System and method for environmentally cleaning a package for a heat transfer decorating machine

ABSTRACT

A heat transfer decorating machine is disclosed. In particular, the disclosed heat transfer decorating machine provides mechanisms to allow the machine to be rapidly re-configured from applying labels to a particular article configuration to applying labels to a different article configuration by an operator without substantial use of tools. In addition, the disclosed heat transfer labeling machine features a distributed drive system which provides a motor for all major movable mechanical elements rather than use a centralized drive system with a distributed transmission. Further, the disclosed heat transfer decorating machine is capable of labeling filled and chilled articles by providing for removal of environmental contamination prior to application of the labels.

REFERENCE TO RELATED APPLICATIONS

The following co-pending and commonly assigned U.S. Patent Applicationshave been filed on the same date as the present application. Theseapplications relate to and further describe other aspects of theembodiments disclosed in the present application and is hereinincorporated by reference:

-   -   U.S. patent application Ser. No. 10/389,008, “SYSTEM AND METHOD        FOR CONFIGURING A HEAT TRANSFER DECORATING MACHINE FOR DIFFERENT        PACKAGE CONFIGURATIONS”, filed herewith; and    -   U.S. patent application Ser. No. 10/389,001, “DISTRIBUTED DRIVE        SYSTEM AND METHOD FOR A HEAT TRANSFER DECORATING MACHINE”, filed        herewith.

REFERENCE TO APPENDIX

Appendices A and B are included herein. Appendix A includes an exemplaryconfiguration for a programmable logic controller according to oneembodiment. Appendix B includes an exemplary programming configurationfor a motion controller according to one embodiment. The included filesof Appendix B are:

Creation Date File Size (bytes) File Name 03/07/2003 64,386 MAIN.bas02/21/2003 14,899 PDP_COMM.bas 03/10/2003  6,716 platen curve.txt02/24/2003   329 SERVO_RESET.bas 03/07/2003   432 STARTUP.bas 03/04/200310,867 WM1_DANCER.bas 03/04/2003 25,858 WM1_MAIN.bas 03/04/2003  1,402WM1_MROLL.bas 03/05/2003  3,412 WM1_REGIST.bas 03/03/2003 10,853WM2_DANCER.bas 03/05/2003 25,837 WM2_MAIN.bas 03/02/2003  1,364WM2_MROLL.bas 03/05/2003  3,429 WM2_REGIST.bas

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightrights whatsoever.

BACKGROUND

Numerous decorating techniques are known in the art, some of whichinclude the application of a label onto a hollow article to bedecorated. One of the techniques which is desirable in this type ofdecorating is the usage of a heat transferable label which includes adecorative predetermined design thereon and may thus be transferred ontothe article or container being decorated.

The heat transfer process permits for multicolored designs to be appliedto a container in a single operation. The heat transfer process involvesthe use of a release-coated carrier upon which the design to betransferred is printed. The design is transferred from the web-likecarrier to the container generally by using a combination of heat andpressure. The principal advantage of the heat transfer technique is thatmulticolored designs of an infinite variety may be applied to acontainer.

Because of the heat requirements associated with the release andapplication of the label from the web onto the container, it has beengenerally accepted practice to maintain the container in a stationaryposition, albeit rotatable in the instances of circular containers,during the decorating step. This has resulted in numerous prior arttypes of apparatus which employ intermittently moving mechanisms whichinclude one to engage and deposit a container at a decorating station.Yet another mechanism engages the container at a decorating station.This latter mechanism must permit relative movement between thecontainer and die to facilitate application of the label onto thecontainer to be decorated. Once the container has been decorated it isremoved from the decorating station by yet another mechanism andconveyed to another destination. Each of these functions has requirednumerous types of moving parts and mechanisms to impart the desiredmotion and transfer of the container to and from a decorating station.

Because of the intermittent movement associated with such systems, thespeed of decoration has been limited. The various movements havecurtailed operating speeds and placed heat transfer labeling systems ina limited and low rate of production category.

Other prior art heat transfer label systems have been devised whichovercome the disadvantages of these machines and provide for a systemwherein articles are decorated in a continuous manner.

FIGS. 1-4 show various perspective views of a heat transfer labelingmachine of the prior art. The article to be decorated by the depictedheat transfer labeling apparatus is illustrated in the form of anirregular shaped container 10. The container 10 is moved in thedirection of the arrow (FIG. 1) to a decorating station indicatedgenerally at 20 at which a label 11 is applied. Label 11 is carried todecorating station 20 by a release coated carrier web 12 which includesthereon a plurality of spaced labels 11 and registration marks 13disposed between labels on the top portion of web 12.

Container 10 is conveyed toward the decorating station 20 by an endlessbelt 21 which passes over drive wheels 22 and 23. Mounted within theendless belt 21 is a vacuum chamber 24 which has its upper surface inengagement with the inside portion of the belt 21. Disposed in thecenter of the belt 21 are a plurality of spaced apertures 25 whichpermit a vacuum to be applied to the bottom of the container 10 thusholding and stabilizing the container during conveyance. Disposedadjacent to the end portion of belt 21 is a feedscrew 26 which has apitch suitable for engagement with the particular size container 10. Thecontainer 10 is engaged by the threaded portion of screw 26 and fed to areceptacle holding means 30. To facilitate feeding of container 10 intoreceptacle holding means 30, is a horizontal transfer plate 31 disposedat the end of belt 21 to assist in transposing the container from theconveyor belt 21 into the receptacle 30.

Receptacles 30 are fastened to an endless chain 32 which is driven oversprockets 33, 34, 35, 36, 37 and 38. Chain 32 is a link type to whichthe receptacle 30 is fastened. Receptacle 30 consists of split halves 39and 39 a (FIG. 1) which have a deep dish contour which substantiallymatches the bottom portion of the container 10 being decorated. Thecontainer 10 is fed by feedscrew 26 into the receptacle 30 with theleading bottom edge of the container engaging the leading or forwardhalf 39 of the receptacle 30 (see FIG. 1). As the container movesforward and while still engaged with the feedscrew 26, chain 32 movesover sprocket 37 with the trailing half 39 a of the receptacle 30 movingup and into holding engagement with the bottom of the container 10.

While the lower portion of container 10 is being moved into receptacle30, the upper open portion of the container is moved into engagementwith a cup-shaped inflating nozzle 40. A plurality of spaced nozzles 40are fastened to a timing belt 41 which passes over gears 42, 43, 44 and45, each of which has external teeth matching those provided on theinterior of timing belt 41. Also, drive gears 46 and 47 (FIG. 1) engagetiming belt 41 and are mounted in adjustable support members 48 whichpermit adjusting the tension of timing belt 41. The remaining gears 42through 45 are suitably mounted in bushings 49. Disposed between theupper and lower portions of timing belt 41 is a manifold 50 tofacilitate inflating container 10 while at the decorating station 20.

A plurality of cup-shaped nozzles 40 are spaced from one another ontiming belt 41 and include a container engaging portion 51. (FIG. 1) Thecenter portion of cup 51 is recessed and of a size compatible forengaging the top opening of the container 10. Cup 51 is preferablyfabricated from a nylon material. Bushing 52 is threaded into the centerof cup portion 51 and serves to fasten the cup to timing belt 41. Inorder to permit passage of the rearward extending portion of bushing 52,gears 42-47 are recessed and do not engage the center portion of timingbelt 41 which is similarly recessed. Bushing 52 has a circular shapedrearwardly extending portion which has a diameter just slightly lessthan the width of a groove provided in the lower portion of manifold 50.In this manner, the groove serves as a guide when timing belt 41 is inengagement with the lower portion of manifold 50. Air is thus permittedto enter the container 10 while at the decorating station 20.

Supports 66 are provided for guiding the containers 10 as they travel oninput and exit conveyors 21 and 60. Also, when only one side of acontainer is being decorated further support may be provided forcontainers 10 while at the decorating station by providing a verticallyoriented endless belt 29 for engaging and supporting the side of thebottle not being decorated.

Once the container leaves decorating station 20, at which label 11 wasapplied, it is routed onto exit conveyor 60. A vacuum chamber 61 is alsodisposed between the upper and lower surfaces of conveyor belt 60 whichis driven about wheel 62 and a similar one disposed at the other endthereof. Belt 60 contains slots 63 in the center portion thereof topermit the application of a vacuum to the lower portion of the container10. Container 10 is discharged from the receptacle 30 as the leadingportion 39 moves downward and out of engagement with container 10 afterthe receptacle passes over sprocket 34. While the trailing half 39 a ofthe receptacle 30 is still in engagement with the container, the forwardportion of container 10 is moved onto plate 65 which is disposed betweenendless chain 32 and exit conveyor 60. While on plate 65, movement ofcontainer 10 is controlled by the trailing container which tends to pushthe container onto plate 65 and then conveyor 60. As the receptacle 30drops out of engagement with the container, inflating nozzle 40 issimilarly disengaged from the open top portion of container 10. As eachnozzle 40 passes over gear 43, it is moved in an upward directiontowards the next pulley 42. This thus causes the recessed portion ofnozzle 40 to lift out of engagement from container 10. The decoratedbottle which exits from conveyor 60 is then ready for filling or otherfurther processing. It is noted that the speeds obtainable with the heattransfer labeling apparatus of this invention (over 200 labels perminute) make the equipment suitable to serve as an in-line piece ofequipment along with filling machines and associated equipment.

The drive system for the various conveyors will be described withparticular reference to FIGS. 3 and 4. A variable speed DC drive motor70 is provided in each module to drive the article and label movingmembers. Motor 70 is continuously operated and as required, engaged anddisengaged from the drive system by means of a clutch 70 a. The outputof drive motor 70 is transmitted to a mechanical speed controller gearbox 71 by means of chain and sprocket drive 72. Output from themechanical gear box 71 drives a web metering roll 73, the output driveshaft including thereon a clutch-brake 74. Another output from the drivemotor 70 is coupled by chain and sprocket drive 75 to gear box 76. Also,by means of chain and sprocket coupling 77 which is connected to a rightangle gear-box 78, drive motor 70 is mechanically coupled to a similardrive motor of an adjacently spaced module. The adjacently spaced moduleis identical to the one herein described and as will be described later,is utilized to decorate two sides of the same article. Sprocket 79 ismechanically connected to a similar sprocket on an adjacent module, thusproviding a direct mechanical linkage of the DC drive motors 70.

Output shaft 80 from the gear box 76 drives the transfer roller cams 81and 81 a mounted on a common shaft by means of the chain and sprocketdrive 82. Cams 81 and 81 a, and the manner in which they serve to drivethe label transfer rollers, will be more fully described hereinafter.Another chain and sprocket drive 83, connected to output shaft 80,drives gear box 84 which in turn has its output driving the chain andsprocket 85. Shaft 86 is driven at one end by chain and sprocket 85while another chain and sprocket drive 87 is thereby driven to providean input drive to gear box 90 which in turn is employed to drive thevarious conveying mechanisms. In this respect, shaft 91 in addition todriving gear box 90 has its output at the other end coupled to thefeedscrew 26 via chain and sprocket drives 92 and 93. The conveyor 21 isdriven by drive wheel 22 which is driven from one output of the gear box90 by means of chain and sprocket drives 94 and 95. Gear 43 drives theinflating nozzle timing belt 41 with gear 43 being driven by the sameoutput from gear box 90 as is sprocket 34 for driving receptacle chain32. Sprocket 34 for chain link belt 32 is driven by the chain andsprocket drive 96 coupled to the output from gear box 90 whereas gear 43is driven therefrom via chain and sprocket drives 97 and 98. Also drivenfrom the same output of gear box 90 is discharge conveyor belt 60 whichis driven by the chain and sprocket 96 which in turn is coupled to thechain and sprocket 99 which drives the chain and sprocket 100. Thus isprovided a synchronized conveying system for continuously carryingarticles 10 through the apparatus with the various speeds regulatedwhile driven from a single source.

Further driven from the same DC variable drive motor 70 is the labelcarrying web 12. A control panel 101 is provided on the module toregulate the speed of the motor 70 which as previously mentioned, drivesthe web metering roller 73 through the clutch-brake 74 and gear box 71.Transfer roller cams 81 and 81 a are driven directly from the main motorvia gear box 76, shaft 80 and chain and sprocket drive 82 which isconnected to shaft 102. The output of shaft 102 also drives shaft 103through the chain and sprocket arrangement 104. Tachometer 103 a, drivenoff shaft 103, reads the operating speed of the machine and provides avisual display on module panel 101.

The supply of new labels is provided on supply wheel 110, the dispensingof which is regulated by metering roll 73. The web 12 as it is unwoundfrom supply reel 110 passes over idler roller 111 and then over dancerroll 112, the operation of which will be more fully described below. Theweb next is routed to feed roller 113 and then into the web meteringroller 73 adjacent to which a photocell 122 is disposed. Photocell 122is disposed to be in a position capable of reading registration marks 13and thus control the web feed speed. Web 12 encircles web meteringroller 73 and is fed therefrom through pinch roller 114 over adjustableroller 115. The supply of labels on web 12 is fed by the metering roller73 which has pinch roller 114 adjusted so as to press against it withthe feed dispensed by the metering roll 73 being regulated by anassociated brake 73 a. Metering roll 73 also has an electricclutch-brake 74 which is activated by a photocell (not shown) disposedadjacent the decorating station 20 which in turn determines the presenceor absence of a container at the decorating station. Thus, if no articleis present to be decorated, clutch 74 disengages metering roller 73 andterminates feeding of web 12.

Adjustable roller 115 is manually movable in slot 116 by means of therotatable handle 117. This manual adjustment permits for approximatelabel positioning on the container prior to operation of the machine.

The web being fed by metering roller 73 next passes over idler rollers125, 126, 127 and 128 and is then routed to pass over the elongatedpreheat plate 130 which is electrically maintained at a temperature ofapproximately 200° F. In addition, radiant heater 129, also referred toas a “platen,” is disposed facing the opposite face of the web 11 so asto further preheat the label prior to arrival at the decorating station20. The platen temperature is typically 300-400° F. At decoratingstation 20 are disposed a pair of heated transfer rollers 131 and 132which are adapted to facilitate transfer of the label 11 onto article10. Transfer roller 131 has the outer label engaging surface formed of asilicone rubber material of 35 durometer hardness which is heated to asurface temperature of approximately 130°-250° F. The interior oftransfer roller 131 is iron oxide filled to provide suitableconductivity. In this manner, transfer roller 131 is maintained at atemperature sufficient to cause transfer of the label 11 to the article10. Transfer roller 132 is metallic, preferably copper, having a layerof chrome plating on the surface. Transfer roller 132 is heated to asurface temperature of approximately 500°-600° F. so as to effectrelease of the label 11 from the web 12.

The transfer rollers 131 and 132 are each pivotally mounted and inoperative engagement with cams 81 and 81 a so as to sequentiallyregulate movement of the transfer rollers into and out of engagementwith the article 10 as it arrives at decorating station 20. Cams 81 and81 a are mounted on a common shaft 102 which as previously mentioned isdriven directly from the drive motor 70.

Transfer roller 131 is mounted in heated housing 133 which is pivotallymounted at 134. A cam follower 135 in engagement with upper cam 81controls the article engaging and disengaging movement of the roller131. A spring 136, urges transfer roller 131 and heated housing 133 outof engagement from article 10 except when moved into engagement by meansof cam 81. Transfer roller 132 is similarly pivotally mounted at 137 andhas spring 138 urging the roller out of engagement from web 12. A camfollower 139, coupled to transfer roller 132, engages lower cam 81 awhich thus controls movement of the metallic transfer roller 132.

Web 12 as it leaves decorating station 20 passes over idler rollers 150,151 and 152. The web next passes over dancer roll 153 and then overidler roller 154 onto the rewind reel 155. Disposed adjacent the rewindreel 155 and beneath dancer roll 153 is a proximity switch 156, asimilar switch 157 being disposed adjacent supply reel 110 and beneathdancer roll 112.

A constant amount of drag is imparted to the label supply wheel 110 bymeans of the dancer roll 112 and associated proximity switch 157.Specifically, dancer roll 112 is mounted to pivot about shaft 160 whichhas mounted at its base an arm member 161 which is movable overproximity switch 157. A spring 163 urges dancer roll 112 in a directionof maximum extension of the carrier web length from the supply wheel110, i.e. in a position furthest away from the source of supply asmeasured along the web travel path. Disposed beneath arm member 161 is amagnetically activated proximity switch 157 which in turn regulates thedegree of braking applied by brake 165 which is mounted on the websupply shaft 166. Potentiometer 167 is connected to web supply brake 165and may be manually regulated to initially set the desired degree ofbraking. Subsequently, the movement of dancer roll 112 exerts asubstantially constant force or drag on the web supply wheel 110.

A similar proximity switch 156 is provided for the rewind label roller155. In this connection, dancer roll 153 includes a similar arm disposedover proximity switch 156. Proximity switch 156 however, is connected toclutch 170 which controls movement of take up reel 155 as will be morefully described hereinafter.

Rewind wheel 155 is driven directly by DC motor 70 through gear box 76.In this respect, output shaft 80 of gear box 76 is coupled to clutch 170by means of the chain and sprocket drive 171. The output from clutch 170is coupled to the rewind reel 155 by means of the chain and sprocketdrive 172 (FIG. 4).

The path of travel of label carrying web 12 is traced. Initially the webexits from the label supply wheel 110 and passes over idler roller 111.Dancer roll 112, which is movable from the solid position to the dottedposition, maintains a substantially constant drag on label supply wheel110 by means of brake 165. After passing over dancer roll 112, the webis routed to metering roll 73 disposed adjacent to photocell 122. Feedof the web 12 is regulated by metering roll 73 which in turn isresponsive to a signal from photocell 122 disposed adjacent thereto. Asmentioned, metering roller 73 meters the web supply and is drivendirectly by the electric drive motor 70 via clutch 74 and the associatedbrake 73 a.

After being dispensed from metering roll 73, the web then is routed overthe adjustable roller 115 and then over idler rollers 125, 126, 127 and128 and over preheater 130. Web 11 is next routed through the decoratingstation 20 at which point label 11 is applied to container 10. Asmentioned, transfer roller 131 and 132 are operated in timed relationwith respect to the registration marks with the transfer rollers movingsequentially into and out of engagement with the container 10 responsiveto the movement of cams 81 and 81 a. In this manner, exact registrationis achieved and decoration of the container accomplished with the labelscapable of being applied in a predetermined location with respect to theposition of the seam.

Prior to the initial operation of the machine, adjustment screw 117 isemployed to adjust the positioning of the label 12 with respect to thepositioning of the conveyors. As mentioned, rotation of screw 117 causesa forward or rearward movement of roller 115 thus adjusting the labelposition at decorating station 20. Once manual adjustment is completed,automatic operation is maintained by means of the photocell 122 readingregistration marks 13 as previously described.

A stepping motor is provided with its output shaft 180 coupled to gearbox 71 by means of the chain and sprocket drive 181. Signals provided tothe stepping motor, such as from photocell 122 thus provide forautomatic web speed regulation.

Exemplary heat transfer decorating machines include the DI-NA-CAL® Model700 heat transfer labeling machine, the DI-NA-CAL® Model 2400 heattransfer labeling machine and the DI-NA-CAL® Model 720 heat transferlabeling machine, all manufactured by Smurfit-Stone Container, Corp,DI-NA-CAL® Label Group, located in Cincinnati, Ohio.

More detail regarding the prior art heat transfer labeling machinedescribed above may be found in U.S. Pat. No. 4,180,105, entitled“ARTICLE INFLATING SYSTEM,”, issued Dec. 25, 1979 to Harvey and assignedto Diamond International Corp., now owned by the assignee of the presentapplication; U.S. Pat. No. 4,239,569, entitled “HEAT TRANSFER LABELINGMACHINE,”, issued Dec. 16, 1980 to Harvey and assigned to DiamondInternational Corp., now owned by the assignee of the presentapplication; U.S. Pat. No. 4,275,856, entitled “HEAT TRANSFER LABELINGMACHINE,”, issued Jun. 30, 1981 to Harvey and assigned to DiamondInternational Corp., now owned by the assignee of the presentapplication; U.S. Pat. No. 4,290,519, entitled “ARTICLE SUPPORTSYSTEM,”, issued Sep. 22, 1981 to Harvey and assigned to DiamondInternational Corp., now owned by the assignee of the presentapplication; U.S. Pat. No. 4,806,197, entitled “CONTINUOUS MOTION ROUNDBOTTLE TURRET,”, issued Feb. 21, 1989 to Harvey and assigned toDinagraphics, Inc., now owned by the assignee of the presentapplication; U.S. Pat. No. 5,028,293, entitled “CONTINUOUS MOTION BOTTLEDECORATING APPARATUS,”, issued Jul. 2, 1991 to Harvey and assigned toDinagraphics, Inc., now owned by the assignee of the presentapplication; and U.S. Pat. No. 6,098,689, entitled “PROCESS AND DEVICEFOR DECORATING PACKAGES WITH CONVEX SURFACES,” issued Aug. 8, 2000 toFiwek, all of which are herein incorporated by reference.

As can be seen, the prior heat transfer decorating machines arecomplicated machines which are difficult to install and difficult tomaintain. For example, the centrally driven transmission system of theabove disclosed heat transfer decorating machine drives all of the majormovable mechanical elements from a central motor with the motive forceof the central motor distributed to the various elements via a complexnetwork of drive shafts, pulleys, belts and gears. While thisarrangement reduces costs by reducing the number of required drivemotors and associated control and power requirements, such anarrangement makes initially setting and maintaining synchronizationamong all of the movable elements difficult and resource intensive.Further, the number of intervening parts between the motor and drivenmechanical element introduces inaccuracies and imprecision into themovements of these mechanical elements, limiting the overall speed ofthe machine, and resulting in a lesser-quality final product, i.e. lessaccurate label placement.

Further, while product manufacturers would prefer to have a flexibledecorating machine that they can use for different packageconfigurations, such as labeling different size containers, thedifficulties in modifying the prior decorating machines and theircentralized power transmission system reduces the cost effectiveness ofsuch a use. In addition, many of the parts of the above machine arecarefully tailored to the package configuration being labeled.Re-configuring the decorating machine for a different packageconfiguration is resource intensive process, often involving tearing themachine apart to replace non-adjustable configuration dependent parts,adjust configurable parts and synchronize and fine tune the machine backto an operating status. Such a process often resulted in machinedowntime of over 8 hours in addition to the operator labor involved. Inmodern industries that require hundreds of packages to be labeled everyminute, such downtime represents an intolerable waste of resources.

For example, changing the above mentioned model 700 decorating machinefrom one article configuration to another, requires the following steps(depending upon the differences between the two article configurations,one or more of the following steps may not need to be performed):

Beginning with the machine running package Ai and changing over topackage B:

-   -   1. The operator first turns the gating screw switch to the OFF        position to stop the inflow of articles into the in-feed        section. The operator then allows the remaining product A        articles in process to complete and the machine will cycle stop,    -   2. The operator turns OFF the flamers;    -   3. The Operator then switches the machine to MANUAL mode;    -   4. The operator then jogs the machine to move the heel cup chain        master link to an accessible location. This permits the heel cup        chain to be disconnected and removed;    -   5. The operator then turns the machine power OFF;    -   6. The label/web material is then removed from both web modules;    -   7. The gating screw drive belt guard is removed;    -   8. The gating screw drive belt is removed;    -   9. The gating screw is removed and the drive shaft is removed        from the screw;    -   10. The gating screw support frame is removed from conveyor and        the standoff spacers are exchanged. The support frame is then        re-installed on the conveyor;    -   11. The drive shaft is installed in the new gating screw and the        new gating screw is installed into the support frame for product        B;    -   12. The gating screw drive belt is reinstalled;    -   13. The in-feed conveyor guide rails are moved into position for        Product B.

Performance of steps 1-13 may take approximately 30 minutes;

-   -   14. The in-feed screw drive belt guard is then removed;    -   15. The in-feed screw drive belt is removed;    -   16. The in-feed screw is removed and the drive shaft is removed        from the screw;    -   17. The guards from around both web modules are then removed;    -   18. The drive belt linking the two web module drive motors is        disconnected;    -   19. The bolts securing the left hand web module to the tooling        conveyor frame are removed;    -   20. The left hand web module is moved away from the tooling        conveyor frame;    -   21. The hand wheels used to adjust the height of the upper        tooling conveyor frame are removed;    -   22. The guard covering the upper tooling conveyor frame is        removed;    -   23. The belt driving the upper tooling conveyor is removed;    -   24. The driven pulley for the drive belt driving the upper        tooling conveyor is removed;

Performance of steps 14-24 may take approximately 30 minutes;

-   -   25. The upper tooling conveyor's right side horizontal frame        member is removed;    -   26. The nozzle belt for product A is removed from the upper        tooling conveyor frame;    -   27. The drive and driven pulleys for the nozzle belt from        Product A are removed;    -   28. The drive and driven pulleys for nozzle belt for Product B        are then installed;    -   29. The nozzle belt for Product B is installed;    -   30. The upper tooling conveyor's right side horizontal frame        member is then re-installed;    -   31. The driven pulley for the drive belt driving the upper        tooling conveyor are installed;

Performance of steps 25-31 may take approximately 3 hours;

-   -   32. The heel cup drive belt is removed from the right angle        gearbox to the heel cup chain drive pulley;    -   33. The drive and driven pulleys for the heel cup drive belt are        removed;    -   34. The heel cup chain for Product A is broken apart/split at        the master link permitting the heel cup chain to be removed from        the lower tooling conveyor;    -   35. The in-feed and exit dead plates are removed;    -   36. The heel cup chain drive and driven sprockets are removed        from the lower tooling conveyor;    -   37. The heel cup chain drive and driven sprockets for Product B        are installed;    -   38. The drive and driven sprockets for the belt driving the heel        cup chain are installed;    -   39. The heel cup chain for product B is installed;    -   40. The in-feed and exit dead plates for product B are        installed;    -   41. The belt driving the heel cup chain is installed;    -   42. The upper tooling conveyor is then moved to the approximate        operating height for Product B using manually adjustable        jack-screws located on either side of the upper tooling        conveyor;    -   43. The drive belt for the upper tooling conveyor is installed;

Performance of steps 32-43 may take approximately 3 hours;

-   -   44. The platen cam for product A is removed from each web        module;    -   45. The shuttle cam for product A is removed from each web        module;    -   46. The shuttle cam for product B is installed on each web        module;    -   47. The platen cam for product B is installed on each web        module;    -   48. The change gears and swing gears for product A are removed        from each web module;    -   49. The change gears and swing gears for product B are installed        on each web module;

Performance of steps 44-49 may take approximately 30 minutes;

-   -   50. The guard on the upper tooling conveyor frame is installed;    -   51. The hand wheels used to adjust the height of the upper        tooling frame are installed;    -   52. The left hand web module is moved back into position with        the center tooling frame and attached to center tooling frame;    -   53. The drive shaft for the in-feed screw for Product B is        inserted into the screw and the screw is installed;    -   54. The drive belt for the in-feed screw is installed;    -   55. The drive belt linking the two web module drive motors is        connected;    -   56. The guards are installed around both web modules;

Performance of steps 50-56 may take approximately 30 minutes;

-   -   57. Power to the machine is turned on;    -   58. The heel cup chain mechanical zero position is set;    -   59. The nozzle belt to adjusted to align with the heel cups;    -   60. The height of the upper tooling frame is set using two        product B bottles placed in the heel cups using adjustable        jack-screws located at each end of the upper tooling frame set;    -   61. The in-feed screw is timed to the heel cups;    -   62. The shuttle and platen cams are timed to the heel cups;    -   63. Label web is threaded on the web modules;    -   64. Test labeling of some bottles is performed;    -   65. Shuttle cams, platen cams, label height and register        positions are adjusted as needed;    -   66. In-feed and out-feed conveyor speeds are adjusted as needed;    -   67. Pre and post flaming is set up;    -   68. Test labeling of some bottles is performed to test for        quality and adhesion;    -   69. Any adjustments are made as needed and retested;    -   70. The machine is set in AUTO and returned to production with        product B;

Performance of steps 57-70 may take approximately 30 minutes;

Total Performance time: 8.5 hours.

As can be seen, the above re-configuration process is extremely tediousand time consuming and prone to errors. Further, in order to perform amajority of steps, the operator would need at least the following tools:various screw drivers, various hex wrenches, various combination or openended wrenches, pliers, a pry bar, a level and a hammer.

In addition, new packaging technologies are placing new demands on theheat transfer decorating machine. For example, in prior packagingtechniques, the manufacturer of the containers was separate from themanufacturer who was buying and filling the containers (the “filler”)with a particular product. The manufacturer would manufacture thecontainers and ship them to the filler. The filler would then pass thecontainers through a heat transfer labeling machine, such as the machinedescribed above, to label the containers. In regards to food products,the filler would then have to clean and disinfect the containers priorto filling them. Such a cleaning and disinfection processdisadvantageously affected the product flavor and shelf life.

Modern food product manufacturers are now switching to a form of“aseptic” packaging wherein containers are manufactured and filled withthe product in the same environmentally controlled area. This allows themanufacturer to avoid the cleaning and disinfection process, therebysignificantly improving both product flavor and shelf life.Unfortunately, with aseptic packaging, the containers cannot be labeledprior to filling. In addition, the temperature of the containers andproduct within is typically very cold as the products must berefrigerated throughout the manufacturing and filling process to preventspoilage. The labeling process must not significantly alter thistemperature so as to adversely affect the product flavor or shelf life.Further, to maintain environmentally controlled conditions, thecontainer labeling may be required to occur in the same environmentallycontrolled area as where the container manufacturing and filling takeplace.

Accordingly, there is a need for a heat transfer labeling machine whichis capable of being easily and quickly configured to label multiplepackage configurations. In addition, there is a need for heat transferlabeling machine which does not use a centralized power transmission.Further, there is a need for a heat transfer labeling machine which iscapable of labeling filled and, potentially, chilled containers in bothcontrolled and uncontrolled environments.

SUMMARY

The present invention is defined by the following claims, and nothing inthis section should be taken as a limitation on those claims. By way ofintroduction, the preferred embodiments described below relate to anapparatus for applying a heat transfer label to an article. Theapparatus includes an in-feed mechanism, the in-feed mechanism operableto receive the article and remove environmental contamination from thearticle prior to the article having a heat transfer label applied. Inaddition, the apparatus includes a label applicator operative to apply aheat transfer label to the article and a conveyor coupled with thein-feed mechanism and the label applicator and operative to convey thearticle from the in-feed mechanism to the label applicator.

The preferred embodiments further relate to a method for applying a heattransfer label to a contaminated article.

In one embodiment, the method comprises: receiving the contaminatedarticle by an in-feed mechanism; removing the contamination from thecontaminated article; conveying the decontaminated article to a labelapplicator; and applying a heat transfer label to the decontaminatedarticle.

Further aspects and advantages of the invention are discussed below inconjunction with the preferred embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a front perspective view of the label application sectionof a heat transfer labeling machine according to the prior art.

FIG. 2 depicts a front perspective view of the decorating stationaccording to the prior art for use with the heat transfer labelingmachine of FIG. 1.

FIG. 3 depicts the drive controls according to the prior art for usewith the decorating station of FIG. 2.

FIG. 4 depicts a front perspective view of the drive controls accordingto the prior art of the heat transfer labeling machine of FIG. 1.

FIG. 5A depicts a block diagram of a heat transfer label machineaccording to one embodiment.

FIG. 5B depicts a more detailed block diagram of the label applicationsection of the heat transfer label machine of FIG. 5.

FIG. 6 depicts a perspective view of one embodiment of the in-feedsection of the heat transfer label machine of FIG. 5A.

FIG. 7 depicts a more detailed perspective view of a first portion ofthe in-feed section of FIG. 6.

FIG. 8 depicts a more detailed perspective view of a second portion ofthe in-feed section of FIG. 6.

FIG. 9 depicts a second perspective view of a portion of the in-feedsection of FIG. 6.

FIG. 10 depicts a more detailed perspective view of one embodiment ofthe gating screw assembly of the in-feed section of FIG. 6.

FIG. 11 depicts a more detailed perspective view of one embodiment ofthe environmental preparation system of the in-feed section of FIG. 6.

FIG. 12 depicts a more detailed perspective view of a portion of theguide-rails and guide-rail adjustment mechanism, according to oneembodiment, of the in-feed section of FIG. 6.

FIG. 13 depicts a perspective view of one embodiment of the conveyorassembly of the label application section, also referred to as thecenter section, of the heat transfer label machine of FIG. 5B.

FIG. 14 depicts a more detailed perspective view of the upper conveyorassembly of FIG. 13.

FIG. 15 depicts a more detailed perspective view of the lower conveyorassembly of FIG. 13.

FIG. 16 depicts an alternate more detailed perspective view of the upperconveyor assembly of FIG. 13.

FIG. 17 depicts an alternate more detailed perspective view of theconveyor assembly of FIG. 13.

FIG. 18 depicts a top perspective view of one embodiment of the labelapplication assembly of FIG. 5B.

FIG. 19 depicts a bottom perspective view of the web module assembly ofFIG. 18.

FIG. 20 depicts a more detailed top view of a portion of the web moduleassembly of FIG. 18.

FIG. 21 depicts a more detailed perspective view of the platen assemblyof the label application assembly of FIG. 18.

FIG. 22 depicts an alternate more detailed perspective view of theplaten assembly of the label application assembly of FIG. 18.

FIG. 23 depicts a more detailed perspective view of the metering rollerof the label application assembly of FIG. 18.

FIG. 24 depicts a more detailed perspective view of the shuttle assemblyof the label application assembly of FIG. 18.

FIG. 25 depicts an exploded perspective view of the guide rollers usedin the label application assembly of FIG. 18.

FIG. 26 depicts an assembled perspective view of the guide roller ofFIG. 25.

FIGS. 27A-27G depicts a flow chart showing a method of configuring theheat transfer label machine of FIG. 5A to label a particular packageconfiguration according to one embodiment.

FIG. 28 shows a block diagram depicting the various sensors of the heattransfer labeling machine of FIG. 5A.

DETAILED DESCRIPTION OF THE DRAWINGS AND PRESENTLY PREFERRED EMBODIMENTS

The disclosed embodiments relate generally to a heat transfer labelingapparatus and a method of applying a heat transferable label to a hollowor filled article, such as a plastic or glass container, bottle, etc.More particularly, the disclosed embodiments relate to such an apparatusand method wherein the apparatus is capable of being easily and quicklyreconfigured for different package configurations by an operatorsubstantially without the use of tools. In addition, the disclosedembodiments relate to a heat transfer labeling apparatus having adistributed power transmission system. Further, the disclosedembodiments relate to a heal transfer labeling apparatus capable oflabeling both filled and chilled containers, in both environmentallycontrolled and uncontrolled areas.

In one embodiment, the disclosed heat transfer labeling apparatusincludes mechanisms, described in more detail below, which allow theapparatus to be easily and quickly reconfigured to label differentpackage configurations, such as different size bottles, referred toherein as a “changeover.” In a second embodiment, the disclosed heattransfer labeling apparatus includes a distributed power transmissionsystem which places a direct drive servo motor at each major movablemechanical element, as will be described in more detail below, therebyeliminating the complex and difficult to maintain centralized powertransmission system and the associated drive shafts, pulleys, gears andbelts. In a third embodiment, the disclosed heat transfer labelingapparatus is capable of labeling filled and chilled containers in anuncontrolled environment using an environmental preparation stationwhich removes contamination from the container, such as condensation,prior to application of the label. Further, with regards to labelingarticles containing refrigerated food products, the temperature of thecontents is not raised by more than 1° F. due to the labeling process,which ensures that product flavor and shelf life are not adverselyaffected. It will be appreciated that each of the features describedabove may be implemented alone or in combination in a particularembodiment of a heat transfer label decorating machine.

An exemplary heat transfer decorating machine according to the preferredembodiments is the DI-NA-CAL® Model HTD-5000 Flex Line™ Heat TransferDecorating Machine, manufactured by Smurfit-Stone Container Corp.,DI-NA-CAL® Label Group, located in Cincinnati, Ohio. This machinefeatures:

-   -   the ability to label panel bottles from 12 oz to 2i5 gallons;    -   the ability to label containers filled with refrigerated food        products without increasing the temperature of the contents by        more than 1° F.;    -   the ability to handle label rolls up to 16.5″ in diameter, which        is up to 40% more than prior machines;    -   the ability to label containers with curved panels and or        tapered panels;    -   precise flame treating technologies to provide the most        consistent label application environment;    -   digital display of gas and air flow rates for repeatable flamer        settings;    -   electronic monitoring of gas and air mixture to insure that only        properly flamed containers are labeled;    -   the availability of various burner systems for a full range of        plastics and wall thickness;    -   flame monitors on every burner head;    -   a servo motor based drive system for the tooling and label feed        is which increases label placement accuracy and can reduce label        spacing up to 50% or more on the web;    -   label placement accuracy of +/−{fraction (1/32)}″ or better via        servo motor control;    -   faster changeovers. Many changeover elements are a simple        “recipe change”, average change-over time is 20 minutes compared        to 8.5 hours for prior machines;    -   the ability to handle an increased label size for a given panel        size;    -   the ability to label contoured panels with no distortion;    -   minimal tooling per container and simplified changeover which        speeds job changes;    -   an operator control panel which pivots so it can be accessed        from either side of the machine;    -   the ability to handle containers with “pour spouts”;    -   fully automatic operation requiring an operator only for        re-supply, e.g. label roll changes;    -   feed screws which regulate container flow through the machine;    -   the capability of decorating up to 500+ containers per minute        depending upon container size and shape.

Referring now to the figures, FIG. 5A shows a block diagram of a heattransfer label machine 100 according to one embodiment. The machine 100includes an in-feed section 102, a label application section 104, anout-feed section 106 and a system control and human machine interface108. The in-feed section 102 further includes an environmentalpreparation station 110, which will be described in greater detailbelow.

Articles to be labeled are received by the in-feed section 102 wherethey are aligned, oriented, paced and spaced for proper labeling. Thein-feed section 102 may receive articles for labeling from othermanufacturing or packaging equipment. The in-feed section 102 is theinterface between this other equipment and the label application section104. The in-feed section 102 further acts as a buffer between the supplyof articles to be labeled and the label application section 104 so as tosupply articles at the most efficient rate for labeling and not overloadthe label application section 104 equipment. In one embodiment, thein-feed section 102 further includes an environmental preparationstation 110 which decontaminates each of the articles and otherwiseprepares the surface of each of the articles for application of thelabel.

Further details of the in-feed section 102, the label applicationsection 104, and the out-feed section 106 are discussed in detail belowin relation to the various figures.

The system control and human machine interface 108 is coupled with thevarious components which make up the machine 100, as will be describedin more detail below. Herein, the phrase “coupled with” is defined tomean directly connected to or indirectly connected through one or moreintermediate components. Such intermediate components may include bothmechanical, hardware and software based components as appropriate.

The system control and human machine interface 108 comprises controllogic including a programmable logic controller 116 and motioncontroller 118 and a user interface (“U1”) 120. It will be appreciatedthat the functionality of one or more of these components describedherein may be integrated within/performed by a single component. Theprogrammable logic controller 116 and motion controller 118 receiveinput from various sensors (see FIG. 28), e.g. motion sensors, positionindicators, etc., located throughout the machine as well as input fromthe user interface 120 and generates outputs to appropriately controlthe various components of the machine 100 to apply labels to articles asdirected by the operator. The programmable logic controller 116 providesoutput to the user interface 120 to allow the operator to observe theoperation of the machine 100 and make necessary adjustments. Theprogrammable logic controller 116 and motion controller 118 generallyfacilitate automated operation and failure detection. In one embodiment,the system control and human machine interface 108 comprises a SLC 5/05Programmable Logic Controller (“PLC”) 116, manufactured by AllenBradley, a division of Rockwell Automation Corp., located in Milwaukee,Wis.

The system control and human machine interface 108 is coupled with themachine 100 using a network 122. In one embodiment, the network 122 is aProfibus network, an open network solution promulgated by PROFIBUSInternational, located in Karlsruhe, Germany, and the PLC 116 furtherincludes a Profibus compatible interface card which facilitatescommunication between the PLC 116 and the inputs/outputs of the machine100 over a Profibus network 122. The Profibus interface driver comeswith the interface card and is downloaded into the card as directed bythe manufacturer. On the machine 100 side, a Turck BL20 input/outputinterface, manufactured by Turck, Inc., located in Minneapolis, Minn.,interfaces the various I/O components of the machine 100 with theProfibus network 122. This I/O interface includes proprietary softwarewhich must be configured according to the manufacturers specification tofacilitate communications. It will be appreciated that any suitableindustrial networking scheme may be used with the disclosed embodimentsto interface the system control and human machine interface 108 with themachine 100.

An exemplary configuration of the PLC, according to embodiment, is shownin Appendix A. In addition, the system control and human machineinterface 108 further comprises a Model #224 motion controller 118manufactured by Trio Motion Technology, LLC, located in Pittsburgh, Pa.The motion controller is used to control the various servo motors,described in detail below, under control of the PLC 116. An exemplaryprogram configuration for use with the Motion Controller, according toone embodiment, is shown in Appendix B. It will be appreciated that anyappropriate user interface 120 may be used with the disclosedembodiments, such as a touch sensitive display panel compatible with theprogrammable logic controller and motion controller, and appropriatelyconstructed for operation in a manufacturing environment. In oneembodiment, the user interface 120 includes a model HM1900 10 inchgraphic touch screen interface panel manufactured by Maple Systems,Inc., located in Everett, Wash. Further the user interface 120 includesat least one panel of hard-wired selector switches and push-button usedto control particular machine 100 functions as will be appreciated byone of ordinary skill in the art. It will further be appreciated thatalternate input devices may be used and that the functionality of thehard-wired selector switches and push buttons may be incorporated intothe touch panel interface. The user interface 120 includes variousgraphical screens for operator input. The screens implement virtualpushbuttons, selector switches and data entry fields. The user interface120 include software code which generates the displays and links thefunctionality to the PLC's 116 database for operator input. The softwarewhich drives the user interface 120 is proprietary and is purchasedseparately from the manufacturer of the user interface. A filecontaining all the screens and related links to the PLC's database isdownloaded to the user interface 120 in order to get it running andcommunicating to the PLC 116. It will be appreciated that the screendesigns are implementation dependent and that all suitable screendesigns which implement the functionality described herein arecontemplated.

The system control and human machine interface 108, according to oneembodiment, is generally capable of performing the following functions,which are described in more detail below:

-   -   provides for general operator input/control of machine        performance;    -   initiates and maintains machine operation after reconfiguration        for new containers, after re-supplying the machine with        containers and/or labels, as well as after recovery after jams        or other error conditions;    -   detect jams and other error conditions and initiate appropriate        recovery actions, including alerting the operator and/or        initiating automated recovery mechanisms;    -   monitors and reports operating parameters and general machine        performance and statistics;    -   monitors maintenance requirements;    -   manages component synchronization among the various movable        mechanical elements of the machine 100 via position sensors        and/or servo motor feedback and maintains optimal or        operator-set operating speed;    -   monitors environmental parameters and adjusts machine 100        operation accordingly;    -   monitors operator activities and performance, ensures proper        labels are loaded for the article being labeled, ensures that        front labels match back labels; and    -   automates configuration changes for new article configurations,        including automatically homing motorized configurable components        to the proper position appropriate for the container, and stores        multiple configuration settings (a.k.a. “recipes”) for various        article configurations which can be easily recalled, modified or        appended to.

Appendix A shows an exemplary program configuration for the PLCdescribed above. This code is written in a proprietary ladder logiclanguage for device manufactured by Allen Bradley. The manufacturer alsoprovides proprietary software development tools to develop and load thedescribe configuration on the PLC 116. The PLC 116 code can be viewed asthe master or supervisor controller over all other electrical devices.Its job is to process all input data and then pass command instructionsoff to the motion controller and/or other devices. Input data consistsof discrete data from sensors and contact relay closures, analog datafrom process transducers and lastly, operator input data via the humanmachine interface and via hard-wired selector switches and pushbuttons.

The PLC 116 code contains the software structure that enables themachine to be run in various modes of operation, such as Manual Mode,Auto Mode and System Initializing, etc. For example, during SystemInitializing the PLC will instruct the motion controller to initializethe lower tooling conveyor and platens. Once the motion controller hascompleted this task it informs the PLC 116, at this point the PLC 116then instructs the motion controller to initialize the upper toolingconveyor and the web modules. In this manner the machine becomesinitialized. This initialized state is required before the operator canrequest the machine to run in auto, therefore it is solely the PLC thatenables the machine to transition from manual, initialized and into automodes. The PLC handles various other functions such as dynamic phasingin the same manner.

Appendix B shows exemplary program configuration files for the motioncontroller 118. The PLC 116 generally directs and supervises the motioncontroller 118 to perform certain functions related to machineoperation. The motion controller 118 then properly actuates the servomotors to execute those functions, e.g. cam actions or coordinatedmovements. The PLC 116 also initiates automated operation which themotion controller 118 implements. The motion controller 118 alsoutilizes a proprietary programming architecture. The manufacturer of themotion controller 118 provides the software development tools to developand load the software onto the motion controller 118. The software forthe motion controller 118 is set up using a familiar PC windowsoperating system folder concept. When a project is created, a folder isautomatically created which then will contain all of the basic programfiles created for use within that project. In the case of the disclosedembodiments, there is a single folder called “machine_41”. This singlefolder which is viewed as a single project application within the Triosoftware, can be downloaded to the MC224 controller 118 in its entirety.There is no need to individually download the single files one at a timeto the controller 118 (although that can be done if desired). Inparticular, Appendix B include the following program files which arepart of the machine_(—)41 configuration:

-   -   MAIN.bas—this file is used to control manual and automatic modes        for the lower tooling conveyor 112B with integrated platens        1414, upper tooling conveyor 112B and the in-feed screw 1004.        This code also directs automatic operation to all other files        for Auto Start and Auto Clearout functions;    -   PDP_COMM.bas—this file is a communication program file for the        Profibus Network. Its function is to simply serve as software        device driver for the Profibus Interface on the MC224        controller. Data is passed to and from the PLC 116 to the motion        controller 118 via this file. The bulk of this program file was        created by Trio for their Profibus Interface;    -   SERVO_RESET.bas—this file is used to enables manual software        reset of all servo axes;    -   STARTUP.bas—this file is used to start MAIN, PDP_COMM, WM1_MAIN        and WM2_MAIN program files at power up;    -   WM1_DANCER.bas—this file contains the software commands for the        dancer 1428 control logic that adjusts the speed of the supply        1404 and waste 1506 rolls to maintain dancer 1428 position (web        tension) for the first web module 114A;    -   WM1_MAIN.bas—this file contains the software commands that        enables manual and automatic modes for the metering roller 1504,        supply roll 1404, and waste roll 1506 for the first web module        114A;    -   WM1 _MROLL.bas—this file contains the software commands that        cause the metering roller 1504 to accelerate to the match        constant velocity of the container and then decelerate as not to        feed out more than 1 label pitch per 1 container pitch for the        metering roller 1504 of the first web module 114A;    -   WM1_REGIST.bas—this file contains the software commands for        holding label registration for the first web module 114A. This        produces corrections to the metering roller 1504 to maintain the        position of the label centered on the article being labeled.        This program takes into account any drift that could be caused        in the web dynamics (web slip etc.) The correction occurs during        the gap portion between the copy areas on adjacent articles;    -   WM2_DANCER.bas—identical to WM1_DANCER.bas except used for the        second web module 114B.    -   WM2_MAIN.bas—identical to WM1_MAIN.bas except used for the        second web module 114B.    -   WM2_MROLL.bas—identical to WM1_MROLL.bas except used for the        second web module 114B.    -   WM2_REGIST.bas—identical to WM1_REGIST.bas except used for the        second web module 114B.    -   platen curve.txt—this file contains a cam profile, e.g. a list        of data points which represent angular movements of a motor        shaft, i.e. absolute positions along the curve of a cam. This        file is used to control the platen movement. When loaded in the        motion controller, this data permits the motion controller to        emulate the shape and action of a mechanical cam using motor        shaft movements. In one embodiment, the machine 10 may be placed        in a “learn” mode and the platen moved along the contour of a        test article. As the article is moved conveyed along the platen,        movements of the platen are recorded to generate the cam profile        data points. This data is then stored and used to cause the        platen to repeat the recorded motion.

Note, that the above program configuration is designed to operate on amachine that utilizes a metering roller to compensate for web velocityerrors as opposed to a shuttle mechanism, described in more detailbelow.

As will be described below, the major mechanical elements of the machine100 feature dedicated servo motors. In one embodiment, these servomotors, identified below, include model PMA4 or model PMA5 servo motors,manufactured by Pacific Scientific, Inc., located in Rockford, Ill. Eachservo motor includes configurable control logic for configuration andtuning of the particular motor, described below. It will be appreciatedthat the servo motors of the disclosed embodiments must be configured asdirected by their manufacturer prior to use. Further, in one embodiment,each servo motor includes a servo motor amplifier which receivescommands from the motion controller 118 as to particular movements ofthe motor and, in response to those commands, provides appropriate powerto the motor to perform the commanded function. In one embodiment, theservo motor amplifier includes a model S60600-NA amplifier for the PMA4servo motors (discussed below) and model S61000-NA amplifier for thePMA5 servo motors (discussed below), both manufactured by Kollmorgen, adivision of Danaher Motion, Inc, located in Washington, D.C. Eachamplifier includes a separate program configuration file that isdownloaded to the amplifier and which contains specifics on servo motorconfiguration and servo motor tuning, as mentioned above. This file isproprietary to and provided by the amplifier manufacturer.

FIG. 5B shows a more detailed block diagram of the label applicationsection 104 of the heat transfer label machine of FIG. 5. The labelapplication section 104 includes a conveyor assembly 112 and web modules114A, 114B located on either side of the conveyor assembly 112. Theconveyor assembly 112 receives the articles to be labeled from thein-feed section 102 after they have left the environmental preparationstation 110. The conveyor assembly 112 stages each of the articles in aconstrained environment and conveys them past the web modules 114A,114B. As the article passes the web modules 114A, 114B, the web modules114A, 114B apply labels to the front and back sides of the articlesubstantially simultaneously. The conveyor assembly 112 then dischargesthe labeled article to the out feed section 106. It will be appreciatedthat the machine 100 may only have a single web module 114A, 114B orthat only one of the two available web modules 114A, 114B may be in usein the situation where the articles are to be labeled only on one side.

FIG. 6 shows a perspective view of one embodiment of the in-feed section102 of the heat transfer label machine 100 of FIG. 5A. The components ofthe in-feed section 102 are shown in more detail in FIGS. 7-12. Inparticular, FIG. 7 shows a more detailed perspective view of a firstportion of the in-feed section 102 of FIG. 6. The in-feed section 102,as shown in this figure, includes a support structure 302, guide rails304, guide rail clamps 306, conveyor 318 and gating screw assembly 320.FIG. 8 shows a more detailed perspective view of a second portion of thein-feed section 102 of FIG. 6. The in-feed section 102, as shown in thisfigure, includes the environmental preparation station 110, conveyormotor 414 and bead rail 416. FIG. 9 shows a second perspective view of aportion of the in-feed section 102 of FIG. 6.

The support structure 302 provides a framework upon which the machine100 components are mounted. The support structure 302 provides levelingfeet which allow the overalls framework to be leveled relative to thelocation of the machine 100. Further, the support structure providesmultiple mounting positions to which the various machine 100 componentsare attached.

The guide rails 304 constrain the articles along the conveyor 318 andkeep the articles flowing in a straight line through the in-feed section102. At the beginning of the in-feed section 102, the guide rails 304may tapered to facilitate easier delivery of the articles to the in-feedsection 102. There are four guide rails 304: two on either side of theconveyor 318, with each pair arranged in a vertical arrangement toprovide lateral support on both sides of the article with a minimal ofmaterial. It will be appreciated that the guide rails 304 may bereplaced with bars, walls or other suitable mechanical elements toconstrain the articles along the conveyor 318. The guide rails 304 arepositioned based on the configuration of the articles being labeled,i.e. tall article may require the guide rails 304 be set to a higherposition to prevent the articles from tipping over, wide or narrowarticles may require appropriate horizontal adjustment of the guiderails 304 to provide adequate support and prevent binding the movementof the articles along the conveyor 318.

The guide rails 304 are mounted to the support structure 302 by a seriesof guide rail clamps 306, shown in more detail in FIG. 12. Each clamp306 holds both guide rails 304 of the particular pair. It will beappreciated that the number of clamps 306 to mount the guide rails 304,as well as their spacing, is implementation dependent and depends on therigidity of the material which makes up the guide rails 304 as well asthe degree of support the guide rails 304 require to perform theirfunction. In one embodiment, the left hand pair of guide rails 304between the beginning of the in-feed section 102 and the environmentalpreparation station 110 are supported by four clamps 306 while theremaining sections of guide rail 304 pairs are supported by a minimum oftwo clamps 306.

In addition to fixedly mounting the guide rails 304 to the supportstructure 302, the guide rail clamps 306 permit adjustment of the guiderails to conform to particular article configurations. Each of the guiderail clamps 306 features a hand-operated mechanism, such as athumb-wheel and nut arrangement, a dual thumb-wheel arrangement, ahand-crank or lever, which, when actuated, loosens or tightens the clamp306 with respect to a mounting post fixedly attached to the supportstructure 302, obviating the need for tools to move the guide rails 304.When loosened, the clamps 306 permit adjustment of the guide rail 304position. In one embodiment, the guide rail clamps 306 feature anadjustment mechanism which adjusts both guide rails 304 of the pair ofguide rails 304 substantially simultaneously. In an alternateembodiment, each guide rail clamp 306 features a separate adjustmentmechanism for each guide rail 304 of the pair of guide rails 304. In oneembodiment, adjustment is only permitted along a horizontal axis, whilethe vertical position remains fixed (set at the time the machine isinstalled). In an alternate embodiment, adjustment is permitted alongboth the horizontal and vertical axes. In this embodiment, separatemechanisms may be provided to permit independent adjustment of one axiswithout disturbing the other axis. Further, in one embodiment, the guiderail clamps 306 provide stops or stepped positions (not shown) which areset for particular article configurations to allow the operator toeasily move the guide rails 304 for the particular articles beinglabeled. In an alternate embodiment, the guide rails clamps 306 permitunimpeded movement of the guide rails 304. In yet another embodiment,the guide rails clamps 306 feature stops of stepped positions as well asthe ability to allow unimpeded movement for the purpose of fine tuningthe guide rail 304 position and/or initially setting the stops orstepped position.

In one embodiment, each guide rail clamp 306 features its own adjustmentmechanism for tightening and loosening the clamp 306, and each must betightened and loosened accordingly to adjust the entire guide rail 304.In an alternate embodiment, each of the guide rail clamps 306, or aportion thereof, are connected with a single mechanism, such as a lever,which actuates the connected clamps 306 substantially simultaneously,thereby allowing to the operator to loosen or tighten all of the clamps306 for a particular guide rail 304, or pair of guide rails 304,substantially simultaneously.

The conveyor 318 conveys each of the articles, as constrained by theguide rails 304, to the gating screw assembly 320, through theenvironmental preparation station and to the in-feed screw 1004 of thelabel application section 104. The conveyor 318 is driven by theconveyor motor 414. The speed of the conveyor 318 is controlled by thesystem control and human machine interface 108 and is appropriatelymatched to the speed of the other components of the machine 100. In oneembodiment, the conveyor motor 414 is a model VWDM3538 Washdown DutyGear Motor with a model GR0209B037 5:1 gearbox both manufactured byBaldor Electric Company, Fort Smith, Ark.

FIG. 10 shows a more detailed perspective view of one embodiment of thegating screw assembly 320 of the in-feed section 102 of FIGS. 6 and 7.The gating screw assembly 320 includes a screw 308, a motor 310, atransmission 312 and a carriage/chassis 314. The motor 310 comprises analternating current motor having a variable frequency drive which drivesthe rotation of the screw 308 via the transmission 312. In an alternateembodiment, the motor 310 comprises a servo motor. In one embodiment,the motor 310 includes a model VLHF05/T0541-B AC motor manufactured byVL Motion Systems, Inc., located in Oakville, Ontario, Canada. In oneembodiment, the transmission 312 includes a belt and pulley arrangement,not shown, to transfer the motive force of the motor 310 to the screw308. It will be appreciated that other types of transmissions 312 may beused including a direct drive or gear based transmission. In oneembodiment, using the system control and human machine interface 108,which is coupled with, and controls, the motor 310, the screw 308 may beautomatically rotated to a home position when initiating, restarting orrecovering operation of the machine. In this embodiment, the screw 308includes a mechanical feature which is detected by a sensor (see FIG.28), such as a magnetic or mechanical switch or proximity sensor,coupled with the system control and human machine interface 108. Sensingthe mechanical feature of the screw 308 permits the system control andhuman machine interface to learn the position of the screw 308 andcontrol the motor 310 appropriately to rotate the screw 308 to thedesired position.

The screw 308 features threads (not shown) which, as the screw rotates,engages the articles from the conveyor 318 between opposing threads, anddrives the articles forward along the conveyor 318. The screw 308threads are not shown in the figure, however one of ordinary skill inthe art would appreciate that the size, shape and pitch of the screwthreads are dependent upon the configuration of the article to belabeled and the desired spacing to be imparted between articles as theyare conveyed on the conveyor 318. The screw 308 threads are spaced so asto allow only one article between any two opposing threads along thelength of the screw 308. In such a manner, as the screw 308 rotates, itpaces and spaces the articles at a pre-determined rate and distance,based on the rotational velocity of the screw 308 and thread pitch. Asthe articles are delivered to the machine 100 by other unconnectedmachinery or by hand, such flow control is necessary to stabilize theinput of articles and establish a consistent quantity/rate of articlesaccording to the set machine cycle, e.g. 200 articles per minute. Thisfurther allows other mechanical elements of the machine 100 to operateproperly. For example, adequate spacing between the articles isimportant to allow electronic eye sensors (See FIG. 28), mounted on themachine 100 and coupled with the system control and human machineinterface 108, to detect motion and ensure that the articles are movingthrough the machine properly. Further, the screw 308 establishes astable and properly spaced flow of articles through the environmentalpreparation station, preventing bunching-up of the articles which mayimpede the ability to decontaminate them.

As can be seen, the screw 308 is configured, e.g. diameter, threadpitch, etc., for a particular article. Further, the screw 308 must bepositioned properly with respect to the conveyor 318 to properly engagethe articles as described. In one embodiment, the screw 308 is designedto be interchangeable, as described below, to allow it to be swapped outdepending on the configuration of the articles to be labeled. In analternate embodiment, the screw 308 features an adjustable diameterand/or thread pitch, obviating the need to swap it out duringchangeovers.

The screw 308, motor 310 and transmission 312 are all mounted on achassis 314 which permits movement/adjustment of the screw 308, motor310 and transmission 312 as a single unit. This eliminates the need toadjust the motor 310 and transmission separately when adjusting thescrew 308 position. The chassis 314 includes front and rear horizontalrails 322, front and rear horizontal sliders 324, front and rearvertical rails 326 and front and rear vertical sliders 328.

The screw assembly 320 is essentially mounted to the front and rearvertical sliders 328 which slide along the front and rear vertical rails326, respectively. The front and rear vertical rails 326 are supportedby the front and rear horizontal sliders 324, respectively, which sit onthe front and rear horizontal rails 322 respectively, which are fixedlyattached to the support structure 302. The horizontal rail 322 andhorizontal slider 324 arrangement permits horizontal movement of thescrew assembly 320 with respect to the conveyor 318 while the verticalrail 326 and vertical slider 328 arrangement permits vertical movementof the screw assembly 320. In this way, the screw 308 may be adjustedalong either or both of the vertical and horizontal axes. Hand operatedadjustment mechanisms, such as a hand wheel, hand crank or lever, notshown in the figure, are provided, which allow the screw assembly 320 tobe adjusted as described or locked in position. In one embodiment,separate hand operated adjustment mechanisms are provided for thehorizontal and vertical adjustments. Stops or stepped positions may beprovided to aid positioning for specific article configurations, alongwith the ability to fine tune or modify the stop or stepped positions.In an alternate embodiment, horizontal and/or vertical movement ismechanically assisted, such as by a hand crank and gear assembly ormotor. In motorized embodiments, the system control and human machineinterface 108 may be coupled with the motor and with screw assemblyposition sensors to automatically home the screw assembly 320 to thecorrect position for various article configurations.

Further, the screw 308 is designed so as not to require a through shaftor drive shaft running through the length of the screw 308. In oneembodiment, the screw 308 features bearings on either end which matewith mounting points on the chassis 314. One mounting point engages thetransmission 312 while the other mounting point engages a releasablemechanism which holds the screw 308 in place. A release lever 316 isprovided with disengages the release mechanism thereby allowing thescrew 308 to be removed without having to remove a through shaft andwithout the need for tools. This reduces changeover time for the screw308 from 20 minutes to under 5 minutes. As the releasable mechanism isseparate from the horizontal and vertical adjustment mechanisms, thescrew 308 may be changed without affecting the screw 308 positionrelative to the conveyor 318. This further speeds changeovers byeliminating unnecessary adjustments.

Returning to FIGS. 6-9, after the article leaves the gating screwassembly 320, it is conveyed through the environmental preparationstation 110. FIG. 11 shows a more detailed perspective view of oneembodiment of the environmental preparation station 110 of the in-feedsection 102 of FIG. 6. The environmental preparation station 110includes air knives 404A, 404B and flame burners 406 (left flame burnernot shown). As was described above, the environmental preparationstation 110 removes condensation or other contamination from thearticles and oxidizes the article surface prior to labeling to ensureproper label application and adhesion. Such preparation is importantwhere the machine 100 is operating in an uncontrolled environment,especially with articles that are susceptible to contamination, such aschilled articles which are susceptible to forming condensation on theirsurface in non-refrigerated environments. In one embodiment, theenvironmental preparation station 110 is designed to handle articleschilled to 32-40° F. in an environment having a temperature of 70° F.and a relative humidity of 50%.

As the articles move along the conveyor 318 from the gating screw 308,they encounter air knives 404A, 404B mounted on either side of theconveyor 318. The air knives 404A, 404B create a curtain of highvelocity air which blows or sweeps contamination from the surface of thearticles as they pass through. In one embodiment, the air knives 404A,404B include the model 12852-20-.055 Gap 24 inch air knife coupled witha model 19150 10 horsepower blower motor and model 122170-190 blowermotor pulley for regulating the blower motor speed, all manufactured bySonic Air Systems, located in Brea, Calif. The air knives 404A, 404B areangled such that the top of the article encounters the air curtainfirst, with the air curtain sweeping down the article as the articlemoves through. It will be appreciated that other orientations of the airknives 404A, 404B may be used to optimally sweep contamination off of anaway from the articles and to prevent the contamination fromcontaminating the components of the machine 100. Further, air knives404A, 404B which are designed to create specific air flow patterns mayalso be used.

High velocity air is supplied from the room to the air knives 404A, 404Bby a compressor/blower, not shown, via hoses, not shown, coupled betweenthe compressor and the air knives 404A, 404B. Because the compressorwarms the air during compression, the air knives 404A, 404B also help toincrease the article's surface temperature which may also aid thelabeling process. In one embodiment, the air is delivered with avelocity of 25-30,000 feet per minute and a temperature of 115-120° F.Note however that the disclosed embodiments maintain only brief contactwith the warm air generated by the air knives 404A, 404B by moving thearticles through the air curtain at a rate of 200-250 articles perminute to achieve the necessary decontamination and surface warming andavoid raising the temperature of the article contents. The minimum rateat which articles must move through the machine 100 to avoid excessivecontact with treatment areas which may damage the article or appliedlabel depends on the type of article being labeled, e.g. plastic orglass, and the type of label being applied, e.g. based on the labelcomposition, but in one embodiment, the minimum rate is approximately 50articles per minute. It will be appreciated that the rate at whicharticles are moved through the machine is implementation dependent andthat the air knives' 404A, 404B air flow velocity and/or temperature maybe increased or decreased based on the rate and resultant change incontact time with the air curtain, to maintain the desired effects. Forexample, heaters could be provided to further increase the air orarticle surface temperature. In one embodiment, ionized air is blown onto the articles to remove dust, debris or other contaminants.

When labeling empty or otherwise light weight articles, the air knives404A, 404B may be turned off or the air flow/velocity reduced so as notto impede movement of the articles along the conveyor 318. Weightsensors may be provided to detect the article weight and allow thesystem control and human machine interface 108 to adjust the airflow/velocity accordingly.

After the articles pass through the air curtain created by the airknives 404A, 404B, they are conveyed by flame burners 406 located oneither side of the conveyor (both burners not shown) to oxidize thesurface of the article in preparation for labeling. In one embodiment,the flame burners 406 include model 007-845 6″ brass single ribbonadjustable burner units manufactured by Flynn Burner Corp., located inNew Rochelle, N.Y. Oxidation significantly improves label adhesion. Thearticles need only have brief contact with the flame from the burners406 to adequately oxidize the surface. Note that the disclosedembodiments maintain only brief contact with the burners 406 by movingthe articles through the flame generated by the burners 406 at a rate of200-250 articles per minute to achieve the necessary oxidation of thesurface and avoid raising the temperature of the article contents. Theminimum rate at which articles must move through the machine 100 toavoid excessive contact with treatment areas which may damage thearticle or applied label depends on the type of article being labeled,e.g. plastic or glass, and the type of label being applied, e.g. basedon the label composition, but in one embodiment, the minimum rate isapproximately 50 articles per minute. It will be appreciated that, fordifferent labeling rates, alternate methods may be used to ensure thatthe articles receive appropriate contact with the flame burners 406,such as accelerating the article through the flame burners 406 butotherwise moving the articles through the machine at a slower rate. Theflame burners 406 burn a gas air mixture at a temperature ofapproximately 1300° F. The flame burners 406 are located within hoods410 which shield the flame burners 406 for safety. Further, the flameburners 406 are located at a sufficient distance on the conveyor fromthe air knives 404A, 404B such that the air flow/air vortex created bythe knives 404A, 404B does not disturb or otherwise disrupt the flamecreated by the burners 406. In one embodiment, the flame burners are set18 inches from the near end of the air knives 404A, 404B.

The flame burners 406 and hoods 410 are mounted to adjustment mechanismswhich permit the flame burner 406 position and orientation to beadjusted with respect to the conveyor 318 and the articles beingconveyed. The adjustment mechanism allows adjustment along both thevertical and horizontal axes as well as adjustment of the angle of theburner 406 face relative to the conveyor. The burners 406 are mounted tohorizontal shafts 424 which are coupled with vertical shafts 422 by anadjustable couplings 412. the vertical shafts 422 are coupled withhorizontal rails 418 by adjustable couplings 420. The horizontal rails418 are fixedly attached to the support structure 302.

The adjustable couplings 412, 420 feature manually actuated mechanisms(not shown) to allow movement of the burner and lock the position inplace. Such manually actuated mechanisms may include thumb wheels, handcranks or levers. Each adjustable coupling 412, 420 may be independentlyactuated to permit independent adjustment along each of the vertical andhorizontal axes as well as the angle. Adjustable coupling 412 along withhorizontal shaft 424 permit pivoting of the burner 406 in a verticalplane as well as adjustment of the horizontal position of the burner406. Adjustable couplings 412 and 420, in combinations with the verticalshaft 422, permit adjustment of the burner 406 angle in a horizontalplane as well as adjustment of the burner 406 height. Adjustablecoupling 420 in combination with horizontal rail 418 permits adjustmentof the horizontal position of the burner 406. Each of the adjustablecouplings 412, 402, shafts 422, 424 and horizontal rail 418, may featurestops or stepped positions configured for particular articleconfigurations which allow an operator to easily move the burners 406 tohandle different articles. In one embodiment, each of the adjustablecouplings 412, 402, shafts 422, 424 and horizontal rail 418 permit finetuning of the position and/or adjustment or modification to the stops orstepped positions. In yet another embodiment, one or more of the axes ofmovement may be motorized and coupled with the system control and humanmachine interface 108 to provide automated configuration of the burner406 position.

Referring back to FIGS. 6-9, after the articles pass by the flameburners 406, they are conveyed to the in-feed screw 1004 of the labelapplication section 104. The in-feed screw 1004 of the label applicationsection 104 features a low friction bead rail 416 to prevent rotation ofthe articles as they are conveyed along.

The label application section 104 features an additional set of airknives (not shown), similar to the air knives 404A, 404B of the in-feedsection 102, located just before the point of label application, i.e.the platens 1414 and transfer rollers 1416 of the web modules 114A, 114Bof the label application section 104 of the machine 100. In oneembodiment, the second set of air knives include the model 12556-06-.0556 inch air knife coupled with a model 19150 10 horsepower blower motorand model 122170-190 blower motor pulley for regulating the blower motorspeed, all manufactured by Sonic Air Systems, located in Brea,California. In an alternate embodiment, the second set of air knives isnot present. The second set of air knives are located after the in-feedscrew 1004 and as close to the point of label application, i.e. thetransfer roller 1416, as possible, but not too close so as to disruptoperation of the label transfer mechanisms with the air vortex createdby the air knives. In this embodiment, the air knives are locatedapproximately 12 inches from the transfer roller 1416. These additionalair knives (not shown) are identical to the air knives 404A, 404Blocated in the environmental preparation station 110 and are used toensure that condensation has not reformed or contamination has not beenre-deposited on the articles prior to labeling after they pass by theflame burners 406. It will be appreciated that the provision ofadditional environmental preparation stages is dependent upon theimplementation of the machine 100 and the environment in which themachine 100 is located. These secondary air knives also impart additionheat (created by the compression of air) to the article surface/labelpanel which enhances transfer of the decoration from the web to thearticle and adhesion. The additional heat results in only about a 1-2°F. rise in surface temperature to achieve these benefits. In oneembodiment, the air is delivered with a velocity of 15-20,000 feet perminute and a temperature of 115-120° F. Alternatively, a flame burnercould be used instead of or in addition to the air knives to impart thenecessary heat to the article surface. Note however that the disclosedembodiments maintain only brief contact with the warm air generated bythe secondary air knives by moving the articles through the air curtainat a rate of 200-250 articles per minute to achieve the necessarydecontamination and surface warming and avoid raising the temperature ofthe article contents. The minimum rate at which articles must movethrough the machine 100 to avoid excessive contact with treatment areaswhich may damage the article or applied label depends on the type ofarticle being labeled, e.g. plastic or glass, and the type of labelbeing applied, e.g. based on the label composition, but in oneembodiment, the minimum rate is approximately 50 articles per minute. Itwill be appreciated that the rate at which articles are moved throughthe machine is implementation dependent and that the air knives' airflow velocity and/or temperature may be increased or decreased based onthe rate and resultant change in contact time with the air curtain, tomaintain the desired effects. For example, heaters could be provided tofurther increase the air or article surface temperature. In oneembodiment, ionized air is blown on to the articles to remove dust,debris or other contaminants.

After the article has been conveyed through the environmentalpreparation assembly, ibis conveyed to the in-feed screw 1004 of thelabel application section 104. In one embodiment, the guide rails 304along this section of the in-feed section 102/label application section104 utilize a “bead” rail to facilitate movement of heavier filledarticles without imparting rotation on those article which wouldmisalign them for entry to the label application section 104. Note thatthe distance between the environmental preparation station 110 and thein-feed screw 1004 of the label application section 104 isimplementation dependent and must be set so that the articles do not getre-contaminated prior to having the labels applied. As mentioned above,in one embodiment, the label application section 104 features a secondset of air knives (not shown) similar to those used in the environmentalpreparation station to blow off any additional contamination, e.g.condensation, which may have formed or otherwise been deposited on thearticle between the flame burners 406 of the environmental preparationstation 110 and the in-feed screw 1004 of the label application section,as well as impart heat to the surface of the article, as discussedabove. These air knives may be coupled with environmental sensors, suchas temperature and/or humidity sensors which sense ambient environmentalconditions, via the system control and human machine interface 108 tooperate only when necessitated by environmental conditions.

FIG. 13 shows a perspective view of one embodiment of the conveyorassembly 112 of the label application section 104, also referred to asthe center section, of the heat transfer label machine 100 of FIG. 5B.The conveyor assembly 1112 constrains and positions each of the articlesfor application of the labels by the web modules 114A, 114B. Theconveyor assembly 112 is shown in more detail in FIGS. 14-17.

FIG. 14 shows a more detailed perspective view of a portion of theconveyor assembly 112, and in particular, the upper conveyor assembly112A of FIG. 13. The conveyor assembly 112 includes an in-feed screw1004, an upper conveyor assembly 112A and a lower conveyor assembly112B, shown in more detail in FIG. 15, mounted on a support structure1002. The in-feed screw 1004 is mounted on a chassis 1010 and includes amotor 1006 which drives the in-feed screw 1004 via a transmission 1008.The in-feed screw 1004 assembly is identical to the gating screwassembly 320 described above and includes all of the adjustabilityfeatures described, except that the drive motor 1006 is a servo motorinstead of an AC motor for more precise control. For more detail aboutthe in-feed screw 1004 assembly, refer to the discussion above relatedto the gating screw assembly 320. While the motor 1006 is shown drivingthe screw 1004 via a belt and pulley based transmission 1008, it will beappreciated that other types of transmissions 1008 may be used includinga direct drive or gear based transmission. The in-feed screw 1004performs a similar function as that of the gating screw 308, paces andspaces the articles so that they may be properly engaged by the neckcups/nozzles 1014 and heel cups 1104 of the upper and lower conveyors112A, 112B, as will be described below. In on embodiment, the in-feedscrew 1004 drive motor 1006 comprises a model PMA4 servo motormanufactured by Pacific Scientific, Inc., located in Rockford, Ill.

The upper conveyor 112A receives and constrains the top portion of thearticle as the article is positioned for label application. The upperconveyor 112A features a conveyor belt 1012 which is mounted on pulleys1016, 1018, 1020 and 1034. The pulleys 1016, 1018, 1020 and 1034 are allmounted to an adjustable frame 1038 which is turn mounted on rails 1040which are fixedly attached to the support structure 1002. The conveyorbelt 1012 is continuously driven in the direction of product flow by thedrive pulley 1016 which is connected with a servo motor 1036 by atransmission (not shown). A servo motor 1036 is power control systemthat converts a small mechanical motion into one requiring much greaterpower and may include a negative feedback system. In one embodiment, theservo motor 1036 includes a model PMA4 servo motor, manufactured byPacific Scientific, Inc., located in Rockford, Ill. The transmission maybe any one of a pulley/belt, gear or direct drive transmission system.The remaining pulleys 1018, 1020 and 1030 keep the conveyor belt 1012aligned and under proper tension. The conveyor belt 1012 includes neckcups nozzles 1014 which engage the neck of the articles as they are fedforward by the in-feed screw 1004. Once engaged, the neck cups/nozzles1014 serve to constrain the upper portion of the article as it isconveyed to the web modules 114A, 114B as described. Note that idlerpulley 1018 aid in engaging spouted articles in the neck cups/nozzles1014.

In an embodiment of the machine 100 designed to label empty articles,the upper conveyor 112A may features a system to blow air into thearticles through the neck cups/nozzles 1014 of the conveyor belt for thepurpose of providing lateral support to the article during the labelapplication process. Such as system is known in the art and describedabove. For filled articles, such as system is not needed as the productwithin the article provides the requisite lateral support. In oneembodiment, an air support system is provided but is capable of beingdisabled when the machine 100 is labeling filled articles.

The upper conveyor 112A further features a height adjustment mechanismwhich permits the height of the conveyor belt 1012 to be adjustedrelative to the rest of the machine 100, without affecting the belt 1012tension or alignment, so as to properly engage the articles or to allowthe operator to move the upper conveyer 112A out of the way formaintenance or to change the screw 1004. As was described above, theconveyor belt 1012 is mounted on pulleys 1016, 1018, 1020 and 1034. Thepulleys 1016, 1018, 1020 and 1034, as well as the servo motor 1036 areall mounted to an adjustable frame 1038 which is mounted on rails 1040.The rails 1040 are fixedly attached to the support structure 1002 andpermit the adjustable frame to move up and down. The adjustmentmechanism further includes an AC motor 1042 fixedly attached to thesupport structure 1002 coupled with a jack screw 1026 (threads notshown) fixedly mounted to the adjustable frame 1038. In one embodiment,the AC motor 1042 includes a model FM2002-12808 (FCCM-1802-12B) WormGear Actuator Assembly including a C-Face mounting with ¾ horse powerbrake motor, manufactured by Duff-Norton, located in Charlotte, N.C., adivision of Columbus Mckinnon Corporation, located in Amherst, N.Y.Actuation of the AC motor 1042 is transmitted to the jack screw via agear transmission and causes the adjustable frame 1038 to move up ordown depending on the direction of rotation of the AC motor 1042.Further, a hand wheel 1028 is provided to allow the operator to manuallyfine tune the height adjustment. The hand wheel 1028 is directlyconnected to the drive shaft of the AC motor 1042 and, therefore,adjusts the height of the adjustable frame 1038 by the same mechanism.In one embodiment it requires 24 turns of the motor 1042 or hand wheel1028 to move the adjustable frame one inch. A measurement scale or otheroperator feedback device may be provided on the machine to indicate thecurrent height to the operator and aid the height adjustment. In analternate embodiment, a precision motor 1042 such as a servo motor maybe used which can automatically fine tune the position. This heightadjustment mechanism alleviates the need for the operator to manuallymove the upper conveyor assembly 112A, which may be considerably heavy.

Referring to FIG. 28, in one embodiment, the adjustment mechanismfeatures position sensors 2830, 2832, 2834 to determine the position ofthe upper conveyor 112A, thus permitting the system control and humanmachine interface 108 to control the lift AC motor 1042 and automate theadjustment process. The sensors include a limit sensor 2830, a firstposition sensor 2832 and a second position sensor 2834. The limit sensordetermines when the upper conveyor 112A is moved to far up or down. Thefirst and second position sensors 2832 and 2834 are configured to detectwhen the upper conveyor 112A is in the proper position for two differentarticle configurations, thereby allowing a quick change-over of themachine 100 between those article configurations. In one embodiment, thesensors 2830, 2832, 2834 each include Ni-3-EG08-AP6X-H1341 Inductiveproximity sensors, manufactured by Turck, Inc., located in Minneapolis,Minn. The position sensors 2832, 2834 each sense the position of anadjustable stop (not shown) which can be set for a particular articleconfiguration.

Referring back to FIG. 14, as the neck cups/nozzles 1014 of the conveyorbelt 1012 are article specific, changeovers to different articles maynecessitate changing the conveyor belt 1012 to a belt 1012 withdifferent neck cup/nozzle 1014 configuration. The upper conveyor 112Afeatures a quick change feature which allows the belt 1012 to be changedout quickly, e.g. in 3-4 minutes versus 3-4 hours for prior machines. Ascan be seen in the Figures, all of the pulleys 1016, 1018, 1020, 1034are mounted in a cantilever fashion, i.e. mounted to the adjustableframe 1038 on only one side. This permits the belt 1012 to be easilyremoved form the open side. Idler pulleys 1020 are mounted on movableslides 1030 which move on rails 1032 which are fixedly attached to theadjustable frame 1038. Actuation of the release mechanism 1022 on eachslide 1030 allows the slide 1030 to move down, thereby loosening thebelt 1012 and allowing it to be removed. Springs 1024 coupled with theslides 1030 counter-balance the loading so that the slides 1030 do notslide down the rails 1032 to fast or otherwise in a dangerous fashion.Once the new belt 1012 is installed, the operator pushes the slides 1030back up the rails 1032, aided by the springs 1024, to achieve thedesired tension and locks them in position with the release mechanisms1022. While the disclosed mechanism combines the ability to remove thebelt 1012 with the ability to adjust the belt 1012 tension, it will beappreciated that separate mechanisms for releasing the belt 1012 andadjusting the belt tension may be provided.

FIG. 15 shows a more detailed perspective view of the lower conveyorassembly 112B of FIG. 13. The lower conveyor assembly 112B includes aconveyor belt 1122 mounted on pulleys 1124 which are mounted on anadjustable frame 1120. the conveyor belt is driven by a servo motor1118, shown in FIG. 17, via one of the pulleys 1124. In one embodiment,the servo motor 1118 includes a model PMA4 servo motor, manufactured byPacific Scientific, Inc., located in Rockford, Ill. The conveyor belt1122 includes two parallel chains to which several heel cups 1104 areattached. As the conveyor belt 1122 moves, the heel cups 1104 engage thebottom of the articles as they are pushed forward by the in-feed screw1004 and constrain the bottom portion of the articles as they are movedpast the web modules 114A, 114B for label application.

The lower conveyor assembly 112B features a belt 1122 tension adjustmentfeature which allows the tension of the conveyor belt 1122 to beadjusted. The adjustable frame 1120 is mounted on a hand operatedscissor lift mechanism 1110 which has a hand crank 1112. The scissorlife mechanism 1110 is fixedly attached to the support structure 1002.Actuation of the hand crank 1112 causes the scissor lift mechanism 1110to move up or down thereby increasing or reducing the tension of theconveyor belt 1122.

The lower conveyor assembly 112B height is adjusted relative to the restof the machine 100, and, in particular, the in-feed screw 1004 using theleveling feet 1114 of the support structure 1002.

For changeovers to different article configurations, an operator needonly uncouple one portion of the conveyor belt 1122 and remove the belt1122 from the frame 1120. The new belt 1122 is then threaded in aroundthe pulleys 1124 and the ends coupled together. In one embodiment, thelower conveyor belt 1122 may be uncoupled with only the use of a smallscrewdriver or needle nose pliers, which is the only tool required forthe entire change-over process. In an alternate embodiment, the lowerconveyor belt 1122 may be uncoupled without the use of tools.

To support various article configurations, the pulleys 1124 featureoutboard bushings 1116 which allow additional pulleys, not shown, to bemounted on the outside of the adjustable frame 1120. this permits awider conveyor belt 1122 with outboard chains that support wider heelcups to be utilized, thereby allowing for wider articles to be labeled.

FIG. 16 shows an alternate more detailed perspective view of the upperconveyor assembly 112A of FIG. 13. FIG. 17 shows an alternate moredetailed perspective view of the conveyor assembly 1112 of FIG. 13,showing the servo motor 1118 which drives the lower conveyor 112B.

The conveyor assembly 112 discharges the labeled articles to an out-feedconveyor, not shown, which conveys the articles to additionalmanufacturing or packaging steps. The out-feed conveyor is similar tothe in-feed conveyor 318 and is driven by an AC motor. In oneembodiment, the out-feed conveyor motor includes a model VWDM3538Washdown Duty Gear Motor with a model GR0209B037 5:1 gearbox bothmanufactured by Baldor Electric Company, Fort Smith, Ark. Furtherprocessing of the labeled articles may be performed while they areconveyed on the out-feed conveyor. For example, a post labeling flameburner may be provided which is similar to the flame burner 406 of theenvironmental preparation station 110. In one embodiment, multiplepost-labeling flame burners are provided. The post labeling flame burneris used to re-flow residual wax on the label and transform a frostyappearance into a glossy or matte appearance of the label (dependent ontype of wax utilized in the heat transfer substrate). The post-labelingflame burner also ensures that optimum label adhesion is achieved byensuring that the label adhesive is set. In one embodiment with one ormore post labeling flame burners, the articles pass through this flameburner at a rate between 200-250 articles per minute to achieve thedesired effects. This rate may be adjusted independent of the overallmachine 100 labeling rate depending on conditions, such as the amount ofresidual wax and/or environmental conditions. The minimum rate at whicharticles must move through the machine 100 to avoid excessive contactwith treatment areas which may damage the article or applied labeldepends on the type of article being labeled, e.g. plastic or glass, andthe type of label being applied, e.g. based on the label composition,but in one embodiment, the minimum rate is approximately 50 articles perminute.

FIG. 18 shows a top perspective view of one embodiment of the web moduleassembly 114A, 114B of FIG. 5B. The web module assemblies 114A, 114B aremirror images of each other but otherwise identical and are mounted oneither side of the conveyor assembly 112 and applies the heat transferlabels to the articles as they are conveyed by the web module assemblies114A, 114B. The web module assembly 114A, 114B includes a supply disk1404, guide rollers 1406A-1 and 1406 K-M, an adjustable pre-heat andplaten assembly 1424, a shuttle 1408, a registration mark scanner 1426and a bar code scanner 1420, all mounted on a tooling table 1402. Theweb modules assembly 114A, 114B further includes a metering roller 1504and a waste disk 1506, both shown in FIG. 19, also mounted on thetooling table 1402. The web module assembly 114A, 114B is designed toprovide a label ready for transfer to the article to the transfer roller1416 of the adjustable pre-heat and platen assembly 1424 at the precisemoment that the article is conveyed by the transfer roller 1416 by theconveyor 112.

The supply disk 1404 holds the label supply reel, not shown, whichsupplies the web containing the labels. The web is the medium upon whichthe labels are printed and from which they are transferred to thearticles. The supply disk 1404 spins in a counter-clockwise direction asshown and feeds the web into the network of guide rollers 1406. The webis routed around guide roller 1406A and then to guide rollers 1406B,1406C and 1406D. Guide roller 1406B is mounted on a movable dancer 1428which is connected to an encoder, now shown. The encoder reports theposition of the dancer 1428 to the system control and human machineinterface 1108. The dancer 1428 is connected with an air cylinder whichis used to control the position of the dancer 1428 to adjust tension ofthe web. Between guide rollers 1406C and 1406D is a registration markscanner 1426 which senses registration marks printed on the web betweenthe labels. These marks permit the system control and human machineinterface 108 to detect and control the label timing. The registrationmark scanner 1426 is height adjustable to account for different widthweb's as well as different vertical placements of the registration markson the web. The web is then routed from guide roller 1406D to guideroller 1406E and past the bar code scanner 1420. The bar code scanner1420 reads bar coded information printed on the web. Such informationmay include the label type or some other identifier. This informationfrom both web module assemblies 114A, 114B permits the system controland human machine interface 108 to determine if the proper front andback labels are being applied to the articles. As the bar code scanner1420 is capable of scanning a wide area, it is typically not necessaryto adjust the scanner 1420 position for different label webs. The web isthen routed from guide roller 1406E to guide roller 1406F and then toguide roller 1406G which is mounted on the shuttle 1408. As will beexplained below, the pivoting action of the shuttle 1408 compensates forvelocity errors in the speed of the web introduced by the movement ofthe transfer roller 1416. The web is then routed from guide roller 1406Garound guide roller 14061 and in front of the pre-heat plate 1412 of theadjustable pre-heat and platen assembly. The web is the routed aroundthe platen 1414 and the transfer roller 1416 and then to guide roller1406K and then to guide roller 1406L which is also mounted on theshuttle 1408. From guide roller 406L, the web is route to guide rollers1406M and then to the metering roller 1504 and waste take up reelmounted on the waste disk 1506.

As will be described below, the supply reel 1404, shuttle 1408 platen1414 including the transfer roller 1416, the metering roller and thewaste disk are all powered by their own servo motors. All of the servomotors are coordinated by the system control and human machine interface108 with the rest of the machine 100. In one embodiment, these servomotors, identified below, include model PMA5 servo motors, manufacturedby Pacific Scientific, Inc., located in Rockford, Ill.

The adjustable pre-heat and platen assembly 1424 includes guide roller14061, web lift-off mechanism 1418, pre-heater 1410 and pre-heat plate1412, platen 1414 and transfer roller 1416 all mounted on a movableplate 1430 which is movably mounted on the tooling table 1402. Inaddition, the platen 1414 servo motor 1508 and transmission 1524 is alsomounted to the movable plate 1430. The lift-off mechanism 1418 is ahydraulically powered cam actuated mechanism which lifts the web off ofthe pre-heat plate when the machine is idle. This prevents waste ofmaterials. The pre-heater 1410 and pre-heat plate prepare the labeladhesive for application by warming up the web as it passes over thepre-heat plate 1412. In one embodiment, the pre-heat plate 1412temperature is approximately 200-250° F. The platen 1414 heats up thewax component of the label for transfer to the article. In oneembodiment, the platen 1414 temperature is approximately 300-350° F. Thetransfer roller 1416 is the actual point of contact with the article andapplies the label to the article as the article is conveyed by. Theplaten 1414 and transfer roller 1416 are mounted together on a pivotingaccess which is driven by a servo motor so as to follow the contour ofthe article as it passes by. This movement is controlled and adjusted bythe system control and human machine interface 108 allowing automaticadjustment for article configurations with slightly differing contourswithout having manually reconfigure the adjustable pre-heat and platenassembly 1424. The platen 1414 and transfer roller 1416 assembly 2200 isshown in more detail in FIGS. 20-22.

The movable plate 1430 permits the horizontal adjustment of the platen1414 and transfer roller 1416 position without having to move thetooling table 1402, which would be much more difficult. An adjustmentmechanism is provided which allows the movable plate 1430 to be moved orlocked in place. This allows adjustments for article configurationshaving different widths, increasing the variety of articles that can belabeled.

In an alternate embodiment, the platen 1414 and transfer roller 1416 arearranged in a straight line parallel to the direction of the flow ofarticles to be labeled. Instead of pivoting about a single axis, theplaten 1414 and transfer roller 1416 move in a linear fashion towardsand away from the article to follow the article's contour. This permitslabeling of articles with a smaller radius, circular of severe ovalshape. Such movement of the platen 1414 would introduce greatervariations in the web velocity, and therefore may be combined with thelinear shuttle 1408 described below for improved velocity errorcompensation.

The shuttle 1408 is actuated by a servo motor 1526 and pivots about acenter point. The shuttle 1408 performs three major functions: matchesthe label/web velocity at the point of transfer to the article speed;compensates for movement of the platen 1414; and compensates forvelocity errors introduced by the transfer roller 1416. Compensation forplaten 1414 movement and transfer roller 1416 velocity errors isimportant for contoured articles. The shuttle assembly 2300 is shown inmore detail in FIG. 23.

In one embodiment of the machine 100, no shuttle 1408, or associatedservo motor 1526, etc. is provided. In this embodiment, velocity errorsare corrected by the metering roller 1504 described below. Under controlof the servo motor 1518 as controlled by the motion controller of thesystem control and human machine interface 108, the metering roller 1504varies it rate of rotation and rotational direction to compensate forweb velocity errors. The motion controller program configurationprovided in Appendix B is designed to be utilized with such anembodiment. It will be appreciated that, in an embodiment without ashuttle, the web path is appropriately adjusted.

In an alternate embodiment, the shuttle 1408 moves in a linear fashioninstead of pivoting, to compensate for web velocity errors. Lineartravel allows for faster accelerations in the web velocity. A linearshuttle 1408 may be combined with the linear platen 1414 and transferroller 1416 described above. A linear shuttle 1408 would also allow forshorter label repeats, i.e. less space between labels on the web,thereby reducing waste and increasing efficiency.

The metering roller 1504 is designed to move one label's worth of webmaterial on each machine cycle to keep everything synchronized. Themetering roller 1504 can also be used to correct velocity errors. In analternate embodiment, the metering roller 1504 performs thefunctionality of the shuttle 1408 by varying its rotational velocitythereby eliminating the need for the shuttle 1408 and simplifying theweb path. It will be appreciated that the need for the shuttle 1408and/or the ability to utilize the metering roller 1504 to correctvelocity errors in the web, is dependent upon the implementation anddegree of contour present in the articles to be labeled.

FIG. 19 shows a bottom perspective view of the web module assembly 114A,114B of FIG. 18, showing the underside support structure 1502. Shown inthe figure are the adjustable pre-heat and platen assembly 1424, theplaten servo motor 1508 and transmission 1524, the shuttle servo motor1526 and transmission 2402, the supply disk 1404, supply disk servomotor 1510 and transmission 1512, the metering roller 1504, meteringroller servo motor 1518 and transmission 1902, the waste disk 1506,waste disk servo motor 1514 and transmission 1516, angling brackets 1528and angle mechanism 1522.

The angle mechanism 1522 permits the tooling table 1402 to be tiltedwithout having to adjust the support structure 1502 or the leveling feet1520. The side of the tooling table 1402 is mounted to the supportstructure 1502 using angle brackets 1528 which permit the table 1402 totilt. The angle mechanism 1522 includes a threaded post mounted to thetooling table 1402 threaded through a bracket which is mounted to thesupport structure 1502. Nuts on the bracket may be adjusted to tilt thetooling table 1402 up or down. Tilting the tooling table 1402 allows forlabeling of tapered articles. In one embodiment, the tooling table 1402may be tilted up to 6 degrees out of level.

The tooling plate 1402 includes a single plate in which bearingcartridges are mounted for the various rotating parts. Prior toolingplates utilized two plates with bearing sandwiched between the plates,making maintenance and adjustments difficult.

FIGS. 20 and 21 show more detailed views of the adjustable preheat andplaten assembly 1424 of the web module assembly 114A, 114B of FIG. 18.The platen 1414 and transfer roller 1416 assembly includes a heightadjustment mechanism including a height adjustment knob 1602, threadedscrew 1606, backing plate 1608, mounting block 1610 and locking nuts1604. The platen 1414 is mounted to the adjustable pre-heat and platenassembly 1424 by the locking nuts 1604 and the mounting block 1610 whichis threaded around the threaded screw 1606. With the locking nutsloosened, the height adjustment knob 1602 can be turned, turning thethreaded screw 1606 and thereby adjusting the height of the platen 1414and transfer roller 1416. This is useful for fine tuning the height ofthe platen and transfer roller without having to adjust the supportstructure 1502 of the web module assembly 114A, 114B.

FIG. 22 shows an alternate more detailed perspective view of the platenassembly 2200 of the web module assembly 114A, 114B of FIG. 18. Thefigure shows the servo motor 1508 and transmission 1524 which connectsthe servo motor 1508 with the platen 1414 to cause it to pivot. In oneembodiment, the transmission 1524 includes a belt and pulleyarrangement. It will be appreciated that other transmission mechanismsmay be used including direct drive or gear based transmissions. Theplaten 1414 further features vacuum grooves 1802 which are coupled witha vacuum source, not shown. These grooves 1802 suck the web close to theplaten to ensure proper heating of the web.

FIG. 23 shows a more detailed perspective view of the metering rollerassembly 2300 of the web module assembly 114A, 114B of FIG. 18.

The figure shows the servo motor 1518 and transmission 1902 whichconnects the servo motor 1518 with the metering roller 1504 to cause itto rotate. Further, the metering roller 1504 features a locking knob2302, the release of which allows the metering roller 1504 to freelyrotate from the servo motor 1518 to allow for adjusting the web asdescribed below. In the locked position, the locking knob 2302 locks therotation of the metering roller 1504 to the servo motor 1518 via thetransmission 1902. In one embodiment, the transmission 1902 includes abelt and pulley arrangement. It will be appreciated that othertransmission mechanisms may be used including direct drive or gear basedtransmissions.

FIG. 24 shows a more detailed perspective view of the shuttle assembly2400 of the web module assembly 114A, 114B of FIG. 18.

The figure shows the servo motor 1526 and transmission 2402 whichconnects the servo motor 1526 with the shuttle 1408 to cause it topivot. In one embodiment, the transmission 2402 includes a belt andpulley arrangement. It will be appreciated that other transmissionmechanisms may be used including direct drive or gear basedtransmissions.

FIG. 25 shows an exploded perspective view of the guide rollers 1406used in the web module assembly 114A, 114B of FIG. 18. The guide roller1406 includes an top cap 2101, roller 2104, shaft 2106, labyrinth seal2108, bearing 2110 and bottom cap 2112. The guide roller 1406 isdesigned with an enclosed bearing sealed from the environment by thelabyrinth seal. This prevents contaminants from entering the bearingsand increasing their friction. This is important in uncontrolledenvironments, such as a non-refrigerated area where filled and chilledarticles are being labeled and the machine may be exposed to excessivemoisture. FIG. 26 shows an assembled perspective view of the guideroller 1406 of FIG. 25.

FIGS. 27A-G shows a flow chart showing an exemplary method ofre-configuring the heat transfer label machine of FIG. 5A to label aparticular article configuration according to one embodiment.

Beginning with the machine running article configuration A and changingover to article configuration B (Block 2702) (it will be appreciatedthat one or more of the following actions may not need to be performeddepending upon the differences between the two article configurations):

-   -   1. Using the system control and human machine interface 108,        turn gating screw 308 switch (not shown) to OFF position. Allow        residual product A configuration articles, in process, to        complete and machine 100 will cycle stop (Block 2704);    -   2. Press the Auto Cycle Stop push button on control panel of the        system control and human machine interface 108 (Block 2706);    -   3. Turn OFF in-feed flamers 406 and out-reed flamers (if        present) (Block 2708);    -   4. Jog the machine 100 center section 104 from main menu of user        interface of the system control and human machine interface 108        to actuate the lower conveyor 112B and move the heel cup 1104        chain, i.e. lower conveyor belt 1122 master link (not shown) to        an accessible location on heel cup chain return slide (not        shown) (Block 2710);

Blocks 1 through 4 may be performed in approximately 3 minutes;

-   -   5. For each web module 114A, 114B (Block 2712):        -   a. Turn ON web clamps which clamp web in place to guide            rollers 1406 using the system control and human machine            interface 108 (Block 2714);        -   b: Turn OFF roll chucks which lock the web supply rolls in            place on the supply and waste discs 1404, 1506 (Block 2716);        -   c. Cut the web at the supply roll core. Remove Product A            label supply roll (Block 2718);        -   d. Cut the web at the waste roll core. Leave enough material            to wrap once around an empty core. Remove Product A waste            roll. Install an empty core and attach the web to the core            with tape (Block 2720);        -   e. Install the new Product B label supply roll on the supply            roll disc 1404. Tape the new web to the tail of the old web            (Block 2722);        -   f. Remove any slack in web by rotating the supply and waste            roll cores (Block 2724);        -   g. Turn ON the roll chucks using the system control and            human machine interface 108 to lock the rolls to the discs            1404, 1506 (Block 2726);        -   h. Loosen the locking knob 2302 on the top of the metering            roller 1504 (Block 2728);        -   i. Hold the supply roll while turning the roll chucks OFF.            Allow the dancer 1428 to drop gently to its travel limit.            The waste roll chuck will release about five seconds after            the supply roll. Hold waste roll and allow its dancer (not            shown) to move gently to its travel limit (Block 2730);        -   j. Rotate and hold web tracking switch in ‘FWD’ position on            the system control and human machine interface 108. Move web            until the splice at the supply roll has moved onto the waste            roll core, re-tighten the metering roller locking knob            (Block 2732);

Block 5 may be performed in approximately 2 minutes per web module;

-   -   6. Go to “Changeover” screen on the system control and human        machine interface 108. Select “UT Conveyor Height Adjust”. Raise        the upper conveyor assembly 112A to the upper travel limit        (Block 2734);    -   7. Press the motion stop switch on the system control and human        machine interface 108 (Block 2736);    -   8. Remove the bead rail 416 along the in-feed screw 1004 using        hand knobs/hand actuated clamps located on the bead rail 416        mounting brackets and set aside (Block 2738);    -   9. Remove the in-feed screw 1004 for Product A by actuating the        in-feed screw release mechanism (see FIG. 7 with reference to        release lever 316) (Block 2740);    -   10. Break the heel-cup/lower conveyor 1122 belt (chain) at the        master link. Remove the heel cup chain/lower conveyor belt 1122        for Product A (This may require a small screw driver or needle        nose pliers) (Block 2742);    -   11. Remove the nozzle belt/upper conveyor belt 1012 by actuating        release mechanism 1022 for Product A (Block 2744);

Blocks 6 through 11 may be performed in approximately 3 minutes;

-   -   12. Install the heel cup chain/lower conveyor belt 1122 for        Product B by threading the belt 1122 through the framework 1120        and around pulleys 1116 and 1124. Connect the ends of the lower        conveyor belt 1122 at the master link (This may require a small        screw driver or needle nose pliers) (Block 2746);    -   13. Install the nozzle/upper conveyor belt 1012 for Product B by        placing it around pulleys 1016, 1018, 1020 and 1034, pushing        slides 1030 up and locking the release mechanism 1022 (Block        2748);    -   14. Install the in-feed screw for Product B and lock it in place        with the release lever (see FIG. 7, release lever 316) (Block        2750);    -   15. Install the bead rail 416 along the in-feed screw (Block        2752);

Blocks 12 through 15 may be performed in approximately 3 minutes;

-   -   16. Remove the gating screw 308 for Product A utilizing release        lever 316 (Block 2754);    -   17. Adjust the in-feed guide rails 304 to their position for        Product B by loosening all of the guide rail clamps 306 and        moving them from along the support from the first stop to the        second stop. In this embodiment, each of the clamps 306 is        provided with two stops/stepped positions, one for product        configuration A and the other for product configuration B. In        this case, each rail 304 is moved from the first position to the        second position (Block 2756);    -   18. Adjust the pre-flamer flame burners 406 to their position        for Product B. In this embodiment, each of the burners 406 is        mounted on an adjustable mounting 412, 418, 420, 422, 424        provided with two stops/stepped positions, one for product        configuration A and the other for product configuration B. In        this case, each flamer 406 is moved from the first position to        the second position (Block 2758);    -   19. Install the gating screw 308 for Product B by placing it in        the assembly 320 and actuating the release lever 316 to lock the        screw 308 in place (Block 2760);

Blocks 16 through 19 may be performed in approximately 2 minutes;

-   -   20. Adjust the register mark scanners 1426 on the web module        tooling tables 1402 to the stop position for Product B (Block        2762) which accounts for differing web heights and differing        vertical positions of the registration marks printed on the web.        Note that the bar code scanner 1420 is typically capable of        scanning a wide enough area to detect bar codes located in        various vertical positions and therefore does not need to be        adjusted;    -   21. Adjust the post-flamers on the out-feed conveyor (not shown)        to their position for Product B. They are configured in the same        manner as he in-feed flamers 406 (Block 2764);    -   22. Adjust the out-feed guide rails to their position for        Product B. They are configured in the same manner as the in-feed        guide rails 304 (Block 2766);    -   23. Adjust the out-feed top rail vertically to the position for        Product B (Block 2768). The out-feed top rail guides the        articles on the out-feed conveyor at the top of the article and        away from the labeled area so as not to damage or other wise mar        the newly applied label, eliminating the need for guide rails        304 similar to those used on the in-feed section 102. This is        not an issue on the in-feed conveyor as the articles have not        yet been labeled;

Blocks 20 through 23 may be performed in approximately 2 minutes;

-   -   24. Return to “Changeover” screen on the system control and        human machine interface 108 (Block 2770);    -   25. Select the proper product on the Recipe selector switch. As        noted above “recipes” are stored configuration data for all of        the electronically configurable portions of the machine 100        (Block 2772);    -   26. Press the Change Recipe pushbutton and OK on the pop-up        confirmation window. The selected product will appear in the        upper right corner of the system control and human machine        interface 108 display (Block 2774);    -   27. Pull out the motion stop pushbutton on the system control        and human machine interface 108 (Block 2776);    -   28. Press amber power reset button on the system control and        human machine interface 108 (Block 2778);    -   29. Go to the “Main” screen of the system control and human        machine interface 108 and press the reset button (Block 2780);    -   30. Turn ON the flamers using the system control and human        machine interface 108 (Block 2782);    -   31. Place a product B container in a heel cup 1104 just prior to        the label application point (Block 2784);    -   32. Go to the “Changeover” screen on the system control and        human machine interface 108 and select “UT Conveyor Height        Adjust” (Block 2786);    -   33. Press the move to position button to lower the overhead        tooling section 112A toward the top of the container for product        B (Block 2788);    -   34. Manually release the brake on the overhead height adjusting        motor (not shown) (Block 2790);    -   35. Use the hand wheel 1028 on the right side of the machine 100        to fine tune the vertical height of the overhead tooling section        112A with product B (Block 2792);

Blocks 24 through 35 may be performed in approximately 2 minutes;

-   -   36. Label a few containers to check quality and adhesion of the        label (Block 2794);    -   37. Turn ON the gating screw 308 at the system control and human        machine interface 108 (Block 2796);    -   38. Press Auto Cycle Start on the system control and human        machine interface 108 (Block 2798);    -   39. Machine 100 is now ready for production (Block 2800);

Blocks 36 through 39 may be performed in approximately 3 minutes;

Total performance time is approximately 25 minutes.

As can be seen, the above process is much simpler and less timeconsuming the change-over processes for prior heat transfer labelingmachines. In addition, the only tool which may be necessary for theabove change-over is a small screw driver or needle nose pliers to aidin un-hooking the lower conveyor belt 1122 master link. Otherwise thechange-over process may be substantially completed without tools.

FIG. 28 shows a block diagram depicting the various sensors of the heattransfer labeling machine 100 of FIG. 5A. Just prior to the in-feedsection 102 are backlog sensors 2804 and 2806 which detect whether thereare articles to be labeled from the up-stream manufacturing equipment ortoo many articles backed up and waiting to be labeled. The sensors 2804and 2806 are optical sensors which detect the interruption of a beam oflight by articles to be labeled. If the high backlog sensor 2804 istriggered, the up-stream manufacturing equipment is notified too slowthe feed of articles to the machine 100. This avoid a potentiallydamaging influx of articles which exceed the machine 100's capacity. Ifthe low backlog sensor 2806 is tripped, this indicates the presence ofarticles to be labeled such that the gating screw 308 may operate tobring in those articles. If the sensor 2806 is not tripped, then thereare no articles to label and the gating screw is appropriatelydisengaged. In one embodiment, the high and low backlog sensors 2804,2806 each include a T18SP6LPQ T18 Series Retro-reflective Sensor andcorresponding BRT-42D retro-reflective target mounted opposite thesensor, manufactured by Banner Engineering Inc., located in Minneapolis,Minn.

To prevent articles from being burned, a movement sensor 2808 isprovided which looks through the flame generated by the flame burners406. If an article stops or other wise gets stuck between the burners406 more than momentarily (determined based on the rate at which themachine 100 is operating), the sensor 2808 will cause the machine 100and burners 406 to shut down to avoid a fire or other damage. In oneembodiment, the sensor 2808 is an optical sensor and includes a SM312FQDmini-beam beam glass fiber optic sensor and 1AT23S glass fiberlight-pipe manufactured by Banner Engineering Inc., located inMinneapolis, Minn., located across from each other along the in-feedconveyor 318 and opposing each other diagonally through the flameburners 406 so as to be able to see if an article is stopped within theburner 406 area.

After the in-feed flame burners 406, along the conveyor 318 are locatedhigh and low limit sensors 2810 and 2812. These limit sensors 2810, 2812are optical sensors and are used to detect backlogs at the in-feed screw1004 of the label application section 104. The low limit sensor 2810indicates that articles are present for in-feed to the label applicationsection 104. The high limit sensor 2812 indicates a backlog of articlesto the label application section 104 and triggers the gating screw toshut off when such a backlog exists. In one embodiment the sensors 2810and 2812 ach include a T18SP6LPQ T18 Series Retro-reflective Sensor andcorresponding BRT-42D retro-reflective target mounted opposite thesensor, manufactured by Banner Engineering Inc., located in Minneapolis,Minn.

The in-feed screw 1004 features a homing/proximity sensor 2814 whichdetects a homing mark located on the screw 1004 so that the systemcontrol and human machine interface 108 can determine and set the screw1004 position. In one embodiment, the homing mark includes a protrudingstainless steel screw (not shown) and the sensor 2814 includes anNi-3-EG08-AP6X-H1341 Inductive proximity sensor manufactured by Turck,Inc., located in Minneapolis, Minn.

The in-feed section 102 conveyor belt 318 also features a movementsensor 2816 which detects whether or not the belt 318 is moving. Thissensor 2816 operates independent of the motor 414 which drives theconveyor belt 318 so as to detect if the belt 318 gets stuck even if themotor 414 appears to be operating correctly. This prevents the belt 318from stopping and trapping articles within the burners 406. The sensor2816 is a proximity sensor and operates by sensing rotation of a keyedgap (not shown) in the conveyor roller shaft. In one embodiment, thesensor 2816 includes a Bi-1-EH04-AP6X-V331 Inductive Sensor manufacturedby Turck, Inc., located in Minneapolis, Minn.

After the in-feed screw 1004 of the label application section 104, thereare optical sensors 2818, 2820 which detect whether articles movingalong have tipped over. Top sensors 2818 watch for the top of thearticle to pass by while bottom sensors 2820 watch for the bottom of thearticle to pass by. The logic which is coupled with these sensors (partof the PLC 116 configuration described above and in Appendix A) detectswhen the sensors 2818, 2820 are triggered inconsistently with theconfiguration of the articles known to be moving through the machine100. If a tipped bottle is detected, the operator is appropriatelynotified. In one embodiment, the sensors 2818, 2820 each include aSM312FQD mini-beam glass fiber optic sensor and 1AT23S and 1ATR.753Sglass fiber light-pipes manufactured by Banner Engineering Inc., locatedin Minneapolis, Minn., located across from each other, with the topsensor 2818 arranged to sense the passing of the tops of the article andthe bottom sensor 2820 arranged to sense the passing of the bottom ofthe article.

Each of the web modules 114A, 114B features web lift off return sensors2822, registration mark sensors 2824 (referred to as 1426 in FIG. 18),and dancer encoders 2826 and 2828 for the unwind reel 1404 dancer 1428and the rewind reel 1506 dancer (not shown). The web lift off returnsensors 2822 are coupled with the web lift-off mechanism 1418 and sensethe position of the web lift-off mechanism 1418. In one embodiment, theweb lift-off return sensors 2822 include Ni-3-EG08-AP6X-H1341 Inductiveproximity sensors for each articulated arm of the web lift-off mechanism1418, manufactured by Turck, Inc., located in Minneapolis, Minn. Theregistration mark sensor 2824/1426 is described above with reference toFIG. 18. In one embodiment, this sensor 2824/1426 includes a R55FVQColor Mark glass fiber optic sensor and BA1.53SMTA glass fiberlight-pipe manufactured by Banner Engineering Inc., located inMinneapolis, Minn. The dancer encoders 2826, 2828 report the positionsof their associated dancers. In one embodiment, the dancer encoders2826, 2828 include DC25F-B 1V2ME 90 degree Dura-Coder, manufactured byAdvanced Micro Controls, Inc., located in Terryville, Conn.

Descriptions of the proximity sensors 2830, 2832, 2834 which sensemovement and position of the upper conveyor assembly 112A are describedabove with reference to FIG. 14.

Both the upper conveyor belt 1012 and lower conveyor belt 1122 of theupper and lower conveyor assemblies 112A, 112B feature homing sensors2836, 2838 for detecting the position of the belts 1012, 1122 andallowing the system control and human machine interface 108 toautomatically align/home the belts 1012, 1122 when initiating machine100 operation. In one embodiment, the sensors 2836, 2838 each include aSM312FQD mini-beam glass fiber optic sensor and 1AT23S glass fiberlight-pipe manufactured by Banner Engineering Inc., located inMinneapolis, Minn. The sensor 2836 for the lower conveyor belt 1122 isarranged so as to sense the position of gaps between consecutive-heelcups 1104. The sensor 2838 for the upper conveyor belt 1012 is arrangedso as to sense the position of the neck cups/nozzles 1014.

The out-feed section 106 conveyor features a similar sensor arrangementas the in-feed section 102. In particular, the out-feed section 106includes a belt movement sensor 2840, article flow sensors 2842, 2844and an out-feed high backlog sensor 2846. The belt movement sensor 2840performs the identical function as the sensor 2816 for the in-feedconveyor belt 318 and is described above. The out-feed high backlogsensor 2846 is similar to the in-feed backlog sensors 2804, 2806 butdetects when down stream manufacturing equipment is not removingarticles from the out feed conveyor quickly enough. If a backlog isdetected, the sensor 2846 will turn off the out-feed post-labelingburners 2802A, 2802B and 2848A, 2848B to prevent damaging articles whichmay get stuck between the post-labeling burners. This sensor 2846 isalso described above with reference to sensors 2804, 2806. As notedabove, there may be more than one set of out-feed post-labeling flameburners 2802A, 2802B, 2848A, 2848B. For each set of burners 2802A,2802B, 2848A, 2848B, article flow sensors 2842, 2846 are provided toensure that articles do not get stuck in the burners 2802A, 2802B,2848A, 2848B. These sensors 2842, 2846 are identical to the sensor 2808for the in-feed burner 406 and are describe above.

All of the sensors described above are coupled with the PLC 116, asdescribed above. All of the logic which manages these sensors andresponds to their outputs is part of the PLC 116 configuration describedabove and in Appendix A.

Various other sensors may also be present on the machine 100 such assensors which detect open access panels and disable the machine 100 forsafety. While specific types of sensors have been disclosed with respectto specific functions, it will be appreciated that other suitablesensors may be substituted for those disclosed, e.g. mechanicallyactuated sensors may be substituted for optically actuated sensors. Itwill be appreciated that additional sensors may also be provideddepending on the implementation of the machine 100 and that one or moreof the functions performed by the above sensors may be combined into asingle sensor.

It will be appreciated that suitable mechanical dimensions andtolerances for given implementation of the disclosed embodiments may bechosen depending on the design requirements and the capabilities andlimitations of the particular materials and manufacturing processes usedfor the implementation as well as the performance requirements of thespecific embodiment.

In summary, the disclosed embodiments provide the following advantages:

1. All of the major movable mechanical elements of the machine 100 arepowered by dedicated servo motors which eliminates the complicated andinaccurate power distribution system of prior decorating machines:

-   -   Conveyor 318 is powered by AC motor 414;    -   Gating Screw 308 is powered by AC motor 310;    -   In-feed Screw 1004 is powered by servo motor 1006;    -   Upper conveyor 112A is powered by servo motor 1036;    -   Upper conveyor 112A height is adjusted by AC motor 1042;    -   Lower conveyor 112B is powered by servo motor 1118    -   Web Supply Disk 1404 is power by servo motor 1510;    -   Platen/Transfer Roller 1414,1416 is powered by servo motor 1528;    -   Shuttle 1408 is powered by servo motor 1526;    -   Metering roller 1504 is powered by servo motor 1518; and    -   Web Waste Disk 1506 is powered by servo motor 1514;

This permits more accurate power delivery and more accurate labelplacement as described herein.

2. Gating and In-Feed Screw Support Structure.

The structure packages the drive motor with the screw together so thatis easily adjusted horizontally and vertically without alteration of thepower transmission from the motor to the screw.

In addition, using a dedicated servomotor reduces the drive train to onebelt and pulleys, allowing far more accurate control of rotational speedand position. The prior art drive system was comprised of numerous powertransmission components that added uncertainty to the actual position ofthe screw.

Further, the servo motor is capable of automatically homing to a featurelocated on the screw-shaft. This improves accuracy and reliability andeliminates the need to rotate the screw by hand to position it, forwhich accuracy suffered and was largely dependent on the skill of theoperator.

The support structure can be adapted to provide a timing screw on bothsides of the in-feed conveyor to further improve feed reliability andincrease the range of bottle shapes the machine can handle.

The screw implementation eliminates the through drive-shaft of priorscrews, which necessitated removing the drive-shaft in order to removeand change out the screw, a cumbersome and slow process. Without thethrough shaft, the screw according to the disclosed embodiments providesa simple lever latch for releasing and locking the screw in place.Changeover time is reduced from 20 minutes to a minute.

3. Environmental Cleaning of Product Package.

Air Knives are provided to remove condensation/moisture which makespossible label application to a container with moisture on the surface,such as condensation from a chilled product in the container.

Further, by using ionized air, dust & static buildup may also beremoved, thereby cleaning the container surface so that labeling can besuccessful contaminated environments.

In addition, the air flowing into the knife is warm from compression andcontact with the blower. This heat may be used for raising the containertemperature and ensuring successful heat transfer.

4. Conveyors

The in-feed system and conveyors utilize a rail structure which allowsfor quick changeovers. The rail supports now utilize clamps operatedwith thumbscrews eliminating the need for tools to make adjustments.

5. Flaming System

The flaming system utilizes a single electrode to increase reliability.The current flows from the electrode ground, the burner head in oneembodiment. The current flow is not affected by flow velocity and ismore reliably directed to ground. Using a single electrode eliminatespassing current between multiple electrodes in the flame path whereinthe velocity of the combustion gasses may prevent the proper flow ofcurrent. Further multiple electrodes frequently resulted in arcing togrounded surfaces which disturbed the proper flow of current and madeflame sensing could become very unreliable.

The flaming system also features a quick lock adjustment for quickchangeovers which permits use of hand operated knobs/wheels to move theflamer position along axis individually. Prior flamers were positionedusing tools and making them difficult to adjust with precision by hand.Further, movement of the prior flamer in all axes controlled by a singleadjustment making it difficult to precisely position the flamer.

In one embodiment, a single flaming system is provided to oxidize thecontainer prior to label application. In an alternate embodiment, anadditional post-flaming system having one or more burners, is providedwhich is used to create a glossy or matte finish on the label afterapplication (dependent on type of wax utilized in the heat transfersubstrate). In this embodiment, the articles may pass through theflaming system at a rate between 200-250 articles to properly re-flowthe residual wax on the label and obtain the desired effects.

6. Central Frame

The central frame features an H frame configuration with knees whichpermit custom upper & lower conveyor frames to be used which increasesthe versatility of the design.

7. Upper Conveyor

The upper conveyor features a cantilever design which allows for quickchangeovers. The cantilever arrangement wherein the conveyor's pulleysare attached to the support frame/structure on only one side permitseasy access to the tooling parts for removing or reconfiguring theconveyor. Prior art frames used an enclosed structure without easyaccess to changeover of container specific tooling parts.

The in-feed end of the upper conveyor permits use of spouted bottles.

The upper conveyor features a longer manifold with more ports and longereffective distance which permits wider range of bottle sizes/volumes tobe used when labeling empty containers which require inflation forstability.

The vertical travel adjustment of the upper conveyor is “motor assisted”with a manual fine tuning control. Prior manually operated adjustmentmechanism had very limited range and no feedback as to position. Ameasurement scale is provided in the frame position feedback. In analternate embodiment, the adjustment mechanism features electronicsensing of position and precise motor driven control of position.Further, automated homing may be provided wherein correct positions forseveral products could be stored for automated changeover.

The upper conveyor is operated by a dedicated servo motor which providesincreased precision. Prior upper conveyors were driven through variousgears belts and transmissions tied back to one or two drive motorsshared with the rest of the machine. The dedicated servo motor furtherprovides independent control of the upper conveyor reducing driveposition and velocity errors. Using an independent drive also allows forhandling products which require different velocities between the upperand lower conveyors. Further, combined with the dedicate servo motor forthe lower conveyor described below, the upper and lower conveyors may beautomatically homed to one another and phased to the rest of the machineusing sensors to detect correct positioning of the tooling. Thiseliminates the need of the operator to manually phase the upper conveyorto the lower conveyor and to the rest of the machine.

In addition, servo based upper tooling with sensor for homing may alsobe used to measure center distances of container necks and automaticallyset the machine parameters based on the measurement. This sensing mayalso be used to verify that the correct tooling is installed, properlyconfigured and working properly when operating or when changing over toa different container. Prior machines provided no mechanism for themachine to determine correct tooling center distances.

Servo motors further provide more accurate measure of torque via themotor current which allows accurate and early detection of jams in themachine. In prior systems, jam protection was provided via atorque-sensing device on the main drive shaft to the tooling section ofthe machine. This device was erratic in determining torque overloads andreleasing the drive.

The upper conveyor also features a size and shape which can becustomized to accommodate unusual package sizes and designs.

8. Lower Conveyor

Similar to the upper conveyor, the lower conveyor features a dedicatedservo motor for precision, automated homing of position, the capabilityto automatically measure the heel cup center distance, and sensing jams.

In addition, the size and shape of the lower conveyor may be customizedto accommodate unusual package sizes and designs, as described above.The lower conveyor features mountings which are accessible bothinternally and externally to the frame allowing conveyor belts to besupported by pulleys mounted on the inside or on the outside of theframe. This removes the width limitation on the conveyor belt and allowsfor a wider range of containers to be used.

9. Web Modules

The web modules feature a label feed mechanism which is driven by adedicated servo motor for precision positioning. Prior systems “pushed”web material toward the point of label application while the waste takeup spindle maintained web tension. Fluctuations in tension, in the priorsystems, resulted in label position variation on the containers as wellas image distortion. The web modules of the disclosed machine “pull” theweb material after label application. The dedicated servo motor closelycontrols web velocity and position while web tension is regulated at thesupply spindle, thereby improving label registration accuracy on thecontainer by more than 50%.

In addition, the web modules feature a Label Shuttle which is alsodriven by a dedicated servo motor for precise speed matching of the webwith the container. The servo motor provides flexibility to handle speedmatching without hardware changes. Shuttle changeover from one containerto another is as simple as pushing a button to alter the softwarecontrol of the shuttle servo motor. The servo motor further permits awider range of shuttle travel allowing smaller label repeats whichreduces label costs. Prior machines used a shuttle which included amachined cam, specially designed for each container to be labeled, toregulate the shuttle movement. Changeovers required that this cam bechanged to one appropriate for the new container configuration.

In an alternate embodiment, the Label Shuttle moves in a linear fashionto remove web velocity errors, allowing for greater control range andshorter repeats versus the arcing motion of the disclosed shuttle.Driven by a servo motor system, a shuttle having a linear motion canaccommodate a much larger range of label web repeats.

The web modules also feature a Platen driven by a dedicated servo motorto permit labeling oval containers with greater contour than possiblewith prior machines. Prior machines utilized a machined cam, speciallydesigned for each container to be labeled, to regulate the prior artplaten movement. This cam, combined with a pivoting platen, was verylimited in the variety and severity of ovals that could be followed. Thededicated servo motor for controlling the platen eliminates restrictionscaused by the prior art cam and makes changeovers from one container toanother is as simple as pushing a button to change the softwarecontrolling the servo motor.

In an alternate embodiment, the platen travels in a linear fashion withrespect to the containers being labeled thereby allowing for a greatercontour range and higher labeling speed over the disclosed pivotingarrangement. A variety of linear actuators could be employed to impartthis type of motion.

The platen further features a vertical adjustment control which allowsheight adjustment of the platen by itself leaving critical framepositioning undisturbed. In addition, the platen is removable forquick-changeovers without disturbing the alignment and position of thesupporting structure.

The platen is mounted on an adjustable preheat & platen assembly whichallows for accommodation of a wider range of package sizes. This allowsthe preheat and platen assembly to move relative to the module framethereby increasing flexibility and removing the need to change criticalweb module frame positioning.

Dedicated servo motors for the label feed mechanism/unwind reel,described above as well as the rewind/waste reel provided improved webtension control. Prior machines utilized a simple electric frictionbrake regulated by a dancer providing minimal control. The dedicatedservo motor arrangement permits larger rolls by powering the spindleholding the label roll and more consistent web tension, therebybalancing loads on the metering roller.

The web modules also feature sealed web guide rollers improve rollerlife, especially when operating in non-environmentally controlled areas.The design excludes contaminants prior to reaching the bearings whicheliminates the use of sealed bearings to exclude contaminants which addundesirable friction.

The web modules further feature a single tooling plate and cartridgedesign which simplifies maintenance. Prior machine used a sandwich likestructure of closely spaced tooling plates to support rotating shafts onthe web modules which made servicing difficult in very cramped quarters,for example power transmission belts could not be replaced without firstremoving the rotating shaft. By using a single plate which housesindividual cartridges that space bearings apart for rotating shaftassemblies, the mechanical systems are much easier to access, forexample power transmission belts can be replaced without removing therotating shaft.

The web module also supports larger spools permit larger label supplyrolls, which reduces the frequency of roll changes. In an alternateembodiment, horizontal loading of rolls is incorporated for maximumlabel capacity.

It is therefore intended that the foregoing detailed description beregarded as illustrative rather than limiting, and that it be understoodthat it is the following claims, including all equivalents, that areintended to define the spirit and scope of this invention.

1. A method for applying a heat transfer label to a contaminatedarticle, said method comprising: (a) filling said contaminated articlewith a product characterized by a first temperature; (b) maintainingsaid first temperature within 1° F.; (c) receiving said contaminatedarticle after said filling by an in-feed mechanism; (d) removing saidcontamination from said contaminated article; (e) conveying saiddecontaminated article to a label applicator; and (f) applying a heattransfer label to said decontaminated article.
 2. The method of claim 1,wherein said article comprises a surface characterized by a firstsurface temperature at the time of said in-feed mechanism receiving saidarticle and a second surface temperature at the time said labelapplicator applies said heat transfer label to said article, said methodcomprising: (g) heating said surface of said article such that saidsecond surface temperature is no more than 2° F. above said firstsurface temperature.
 3. The method of claim 1, further comprising: (g)cooling said article prior to said receiving.
 4. The method of claim 1,further comprising: (g) applying said heat transfer label before saidarticle becomes re-contaminated.
 5. The method of claim 1, wherein saidenvironmental contamination comprises condensation.
 6. The method ofclaim 1, wherein said environmental contamination comprises dust.
 7. Themethod of claim 1, wherein said removing further comprises blowing saidenvironmental contamination off of said article.
 8. The method of claim7, wherein said blowing further comprises blowing ionized air.
 9. Themethod of claim 1, wherein said removing further comprises at least oneof evaporating, burning, or combination thereof said environmentalcontamination from said article.
 10. The method of claim 1, wherein saidremoving further comprises sensing ambient environmental conditions andadjusting, automatically, said removal of said environmentalcontamination in response to said sensed ambient environmentalconditions.
 11. The method of claim 1 further comprising: (g) sealingenvironmental contaminants out of said apparatus.
 12. A method forapplying a heat transfer label to a contaminated article, said methodcomprising: (a) receiving said contaminated article by an in-feedmechanism; (b) removing said contamination from said contaminatedarticle; (c) sensing ambient environmental conditions and adjusting,automatically, said removal of said environmental contamination inresponse to said sensed ambient environmental conditions; (d) conveyingsaid decontaminated article to a label applicator; and (e) applying aheat transfer label to said decontaminated article.
 13. The method ofclaim 12, further comprising (f) filling said article with a productprior to said receiving.
 14. The method of claim 13, wherein saidproduct is characterized by a first temperature, said method furthercomprising: (f) maintaining said first temperature within 1° F.
 15. Themethod of claim 14, wherein said article comprises a surfacecharacterized by a first surface temperature at the time of said in-feedmechanism receiving said article and a second surface temperature at thetime said label applicator applies said heat transfer label to saidarticle, said method comprising: (g) heating said surface of saidarticle such that said second surface temperature is no more than 2° F.above said first surface temperature.
 16. The method of claim 12,further comprising (f) cooling said article prior to said receiving. 17.The method of claim 12, further comprising: (f) applying said heattransfer label before said article becomes re-contaminated.
 18. Themethod of claim 12, wherein said environmental contamination comprisescondensation.
 19. The method of claim 12, wherein said environmentalcontamination comprises dust.
 20. The method of claim 12, wherein saidremoving further comprises blowing said environmental contamination offof said article.
 21. The method of claim 20, wherein said blowingfurther comprises blowing ionized air.
 22. The method of claim 12,wherein said removing further comprises at least one of evaporating,burning, or combination thereof said environmental contamination fromsaid article.
 23. The method of claim 12 further comprising: (f) sealingenvironmental contaminants out of said apparatus.
 24. An apparatus forapplying a heat transfer label to an article, said apparatus comprising:an in-feed mechanism, said in-feed mechanism operable to receive saidarticle and remove environmental contamination from said article priorto said article having a heat transfer label applied; a label applicatoroperative to apply a heat transfer label to said article; and a conveyorcoupled with said in-feed mechanism and said label applicator andoperative to convey said article from said in-feed mechanism to saidlabel applicator; wherein said article is filled with a chilled contentcharacterized by a first temperature, said apparatus operative to applysaid label to said article without raising said first temperature bymore than 1° F.
 25. The apparatus of claim 24, wherein said article ischaracterized by: a first surface temperature at the time said in-feedmechanism receives said article; and a second surface temperature at thetime said label applicator applies said heat transfer label to saidarticle; and wherein said second surface temperature is no more than 2°F. above said first surface temperature; and further wherein said firsttemperature of said chilled content is not raised by more than 1° F.during said conveyance.
 26. The apparatus of claim 24, wherein saidconveyor and said label applicator are operative to apply said heattransfer label before said article becomes re-contaminated.
 27. Theapparatus of claim 24, wherein said environmental contaminationcomprises condensation.
 28. The apparatus of claim 24, wherein saidenvironmental contamination comprises dust.
 29. The apparatus of claim24, wherein said in-feed mechanism comprises an air-knife operable toblow said environmental contamination off of said article.
 30. Theapparatus of claim 29, wherein said air knife utilizes ionized air toblow said environmental contamination off of said article.
 31. Theapparatus of claim 24, wherein said in-feed mechanism comprises a heatsource operative to at least one of evaporate, burn, or combinationthereof said environmental from said article.
 32. The apparatus of claim24, wherein said in-feed mechanism comprises a sensor operative to senseambient environmental conditions, said in-feed mechanism being furtheroperative to automatically adjust said removal of said environmentalcontamination in response to said sensed ambient environmentalconditions.
 33. The apparatus of claim 24, further comprising anenvironmental seal operative to keep said environmental contaminants outof said apparatus.
 34. An apparatus for applying a heat transfer labelto an article, said apparatus comprising: an in-feed mechanism,comprising: a sensor operative to sense ambient environmentalconditions; wherein said in-feed mechanism is operable to receive saidarticle, remove environmental contamination from said article prior tosaid article having a heat transfer label applied, and automaticallyadjust said removal of said environmental contamination in response tosaid sensed ambient environmental conditions; a label applicatoroperative to apply a heat transfer label to said article; and a conveyorcoupled with said in-feed mechanism and said label applicator andoperative to convey said article from said in-feed mechanism to saidlabel applicator.
 35. The apparatus of claim 34, wherein said article isfilled.
 36. The apparatus of claim 34, wherein said article is chilled.37. The apparatus of claim 34, wherein said article is filled with achilled content characterized by a first temperature, said apparatusoperative to apply said label to said article without raising said firsttemperature by more than 1° F.
 38. The apparatus of claim 37, whereinsaid article is characterized by: a first surface temperature at thetime said in-feed mechanism receives said article; and a second surfacetemperature at the time said label applicator applies said heat transferlabel to said article; and wherein said second surface temperature is nomore than 2° F. above said first surface temperature; and furtherwherein said first temperature of said chilled content is not raised bymore than 1° F. during said conveyance.
 39. The apparatus of claim 34,wherein said conveyor and said label applicator are operative to applysaid heat transfer label before said article becomes re-contaminated.40. The apparatus of claim 34, wherein said environmental contaminationcomprises condensation.
 41. The apparatus of claim 34, wherein saidenvironmental contamination comprises dust.
 42. The apparatus of claim34, wherein said in-feed mechanism comprises an air-knife operable toblow said environmental contamination off of said article.
 43. Theapparatus of claim 42, wherein said air knife utilizes ionized air toblow said environmental contamination off of said article.
 44. Theapparatus of claim 34, wherein said in-feed mechanism comprises a heatsource operative to at least one of evaporate, burn, or combinationthereof said environmental contamination from said article.
 45. Theapparatus of claim 34 further comprising an environmental seal operativeto keep said environmental contaminants out of said apparatus.